ES2681980T3 - Apparatus for forming three-dimensional objects using linear solidification - Google Patents

Abstract

An apparatus for forming a three-dimensional object from a solidifiable material, comprising: a solidification energy source (90; 90a; 90b); and a linear scanning device (92) in optical communication with the solidification energy source (90; 90a; 90b); characterized in that the solidification energy source (90; 90a; 90b) is mobile in a first direction and operable to project solidifiable energy selectively in a second direction on the linear scanning device (92) while moving in the first direction ; a solidification energy sensor (324) in optical communication with the linear scanning device (92); which is positioned such that the solidification energy sensor (324) can receive energy diverted from the linear scanning device (92); and a linear solidification microcontroller connected to the solidification energy sensor (90; 90a; 90b) and programmed to initialize a timer upon receiving a signal from the solidification energy sensor (324); wherein the linear scanning device (92) is separated from the solidification energy source (90; 90a; 90b) and the solidification energy device (92) is separated from the solidification energy sensor (324), in which The linear scanning device (92) is operable to scan solidification energy received from the solidification energy source (90; 90a; 90b) in a plurality of linear patterns along a solidifiable material source, while the device linear scan (92) moves in a first direction, each linear pattern has a length along the second direction and the solidification energy sensor (324) is operable to receive solidification energy from the solidification energy source ( 90; 90a; 90b) each time the linear scanning device (92) scans a linear pattern of solidification energy along the source of the solidifiable material.

Description

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Description

Apparatus for forming three-dimensional objects using linear solidification CAMPO

The description refers to an apparatus and a method for manufacturing three-dimensional objects, and more specifically, to an apparatus according to claim 1.

DESCRIPTION OF THE RELATED TECHNIQUE

Rapid three-dimensional prototyping and manufacturing allow the rapid and accurate production of components with high precision. The machining steps can be reduced or eliminated using said techniques and certain components can be functionally equivalent to their regular production counterparts depending on the materials used for production.

The components produced can vary in size from small to large parts. The manufacturing of parts can be based on various technologies, including hardening of photopolymers using light curing or photopolymerization methods. Secondary curing can take place with exposure to, for example, ultraviolet (UV) light. A process for converting computer-aided design (CAD) data to a data model suitable for rapid manufacturing can be used to produce data suitable for component construction. A pattern generator can then be used to build the piece. An example of a pattern generator may include the use of DLP (Digital Light Processing Technology) from Texas Instruments®, SXRD ™ (X-tal silicone reflective screen), LCD (liquid crystal display), LCOS (liquid crystal) in silicon), DMD (digital mirror device), JILA de JVC, SLM (spatial light modulator) or any type of selective light modulation system.

Many of the above devices are complex and involve numerous very small moving parts. For example, DMD devices involve thousands of individually controllable micromirrors. Laser-based SLA systems require lasers with a high degree of controlled manipulation to trace object cross sections that can be linear, nonlinear or irregularly shaped. These characteristics of many known three-dimensional object manufacturing systems have increased the cost of such systems, which makes them inaccessible to many consumers. Therefore, the need for an apparatus and a method for manufacturing three-dimensional objects that use a linear solidification process that addresses the above problems has emerged.

From the US patent US 6,151,056 a 2D printer with a fixed laser and a polygonal mirror with a sensor to control the intensity of the laser light is known.

A 3D laser sintering apparatus according to the pre-characterization part of claim 1 is known from the international patent application published under publication number WO 2011/064725 A1, which implies a source of energy beams in the shape of a laser and lens unit and scanning by means of a polygonal mirror. The laser and the polygonal mirror are fixed.

It is an object of the invention to improve the 3D printer according to the precharacterization part of claim 1 by providing a better indication of the location of the laser beam within the solidifiable material.

This and other problems are solved by means of the characteristics of the characterization part in combination with the characteristics of the pre-characterization part of claim 1. Other advantageous embodiments are claimed in the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The description will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a system for making a three-dimensional object from a solidifiable material in a closed housing configuration;

FIG. 2 is a perspective view of the system for making a three-dimensional object of FIG. 1 in an open housing configuration;

FIG. 3 is a representation of an embodiment of a solidification substrate assembly and a linear solidification device for use in a system for making a three-dimensional object with the linear solidification device in a first position along the length of the solidification substrate set;

FIG. 4 is a representation of the solidification substrate assembly and the linear solidification device of FIG. 3 with the linear solidification device in a second position along the length of the solidification substrate assembly;

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FIG. 5A is a perspective view of the back of a linear solidification device comprising a solidification energy source and a rotating energy deflector;

FIG. 5B is a perspective view of the front part of the linear solidification device of FIG. 5B;

FIG. 5C is a schematic view of a first alternative version of the linear solidification device of FIG. 5 A in which the housing is removed and which includes a solidification energy synchronization sensor;

FIG. 5D is a schematic view of a second alternative version of the linear solidification device of FIG. 5 A in which the housing has been removed and which includes dual solidification energy sources and a solidification energy sensor;

FIG. 6 is a side elevational view of a system for manufacturing a three-dimensional object from a solidifiable material, comprising the solidification substrate assembly and the linear solidification device of FIG. 3 and 4;

FIG. 7 is an alternative embodiment of a solidification substrate assembly and a linear solidification device for use in a system for manufacturing a three-dimensional object from a solidifiable material;

FIG. 8 is an exploded view of the embodiment of FIG. 7;

FIG. 9A is an exploded perspective view of a film assembly used in the solidification substrate assembly of FIG. 7;

FIG. 9B is a side elevation view of the film assembly of FIG. 9A;

FIG. 9C is a perspective view of the film assembly of FIG. 9A in an assembled configuration;

FIG. 10 is a cross-sectional view in the foreground of the film assembly of FIG. 7 taken along line 10-10 of FIG. 7 with the solidification substrate support removed;

FIG. 11 is a perspective view of a mobile substrate assembly used in the solidification substrate assembly of FIG. 7;

FIG. 12 is a perspective view of a stripping member assembly used in the solidification substrate assembly of FIG. 7;

FIG. 13 is a close-up side cross-sectional view of the solidification substrate assembly of FIG. 7 taken along line 13-13 in FIG. 7;

FIG. 14 is a graphical representation of three-dimensional object data for use in the illustration of a method for manufacturing a three-dimensional object using a linear solidification device;

FIG. 15 is a graphical representation of data on sheets representative of the three-dimensional object of FIG. 14;

FIG. 16 (a) is a graphical representation of the strip data of the cross-section of objects corresponding to one of the sheets of a three-dimensional object shown in FIG. fifteen;

FIG. 16 (b) is a top plan view of a solidifiable material source comprising a building envelope and lateral displacement regions;

FIG. 16 (c) is a top plan view of the solidifiable material source of FIG. 16 (c) with the strip data of the cross section of the object of FIG. 16 (c) mapped on the building envelope;

FIG. 16 (d) is a table representing exemplary sets of string data corresponding to the strip data of the cross section of the object of FIG. 16 (c);

FIG. 16 (e) is an exemplary representation of the data of the strip of the cross-section of the object mapped onto a construction envelope used to illustrate a method of manufacturing adjacent layers of a three-dimensional object using a linear solidification device;

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FIG. 16 (f) is a table representing exemplary sets of chain data corresponding to a uniform layer of a three-dimensional object represented by the strip cross-sectional data of the chain of FIG. 16 (e);

FIG. 16 (g) is a table representing exemplary sets of string data corresponding to an odd layer of a three-dimensional object represented by the cross-sectional data of the strip of FIG. 16 (f);

FIG. 17 is a perspective view of an alternative embodiment of a solidification substrate assembly and linear solidification device for use in a system to make a three-dimensional object with the linear solidification device in a first position along the length of the solidification substrate set;

FIG. 18 is a perspective view of the embodiment of FIG. 17 with the linear solidification device in a second position along the length of the solidification substrate assembly;

FIG. 19 is a schematic view of an alternative embodiment of a system for making a three-dimensional object using a linear solidification device; Y

FIG. 20A is a detailed view of a part of the system for making a three-dimensional object of FIG. 19;

FIG. 20B is a detailed perspective view of a worktable assembly and linear solidification device of an alternative embodiment of the system for making a three-dimensional object of FIG. 19;

FIG. 20C is a detailed perspective view of the lower part of the worktable assembly and the linear solidification device of FIG. 20B in a turned orientation (bottom up);

FIG. 20D is a cross-sectional side view of a part of the linear solidification device and the solidification substrate assembly of FIG. 20B;

FIG. 21 is a flow chart used to illustrate a method of making a three-dimensional object from a solidifiable material using a linear solidification device;

FIG. 22 is a flow chart used to illustrate an alternative method for making a three-dimensional object from a solidifiable material using a linear solidification device;

FIG. 23 is a flow chart used to illustrate the alternative method of FIG. 22;

FIG. 24 is a graph representing the output signals of the microcontroller to a solidification energy source and a motor used to drive a rotating energy deflector and microcontroller input signals received from a solidification energy synchronization sensor;

FIG. 25 (a) is a view along the scan axis (y) of a hemispherical test piece used to adjust a motor movement parameter in a system to make a three-dimensional object from a solidifiable material in a configuration of closed housing; Y

FIG. 25 (b) is a view along the construction axis (z) of the test piece of FIG. 25 (a).

Similar numbers refer to similar parts in the drawings.

DETAILED DESCRIPTION

The Figures illustrate examples of an apparatus and method for manufacturing a three-dimensional object from a solidifiable material. Based on the foregoing, it should be generally understood that the nomenclature used herein is simply for convenience and the terms used to describe the invention should have the broadest meaning on the part of one skilled in the art.

The apparatus and methods described in this document are generally applicable to the additive manufacturing of three-dimensional objects, such as components or parts (generally described herein as objects), but can be used beyond that scope for alternative applications. The system and methods generally include a linear solidification device that applies solidification energy to a solidifiable material, such as a photo-curable resin. Linear solidification devices apply solidification energy in a generally -and preferably- substantially linear pattern, across an exposed surface of the solidifiable material and also move

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in a direction other than that defined by the length of the linear pattern while solidification energy is applied. In some examples, the linear solidification device includes a scanning device that diverts the solidification energy received in a scanning pattern. Such scanning devices include, but are not limited to, rotating polygonal mirrors and linear scanning micro mirrors.

The apparatus and methods described herein may include a solidification substrate against which a solidifiable material solidifies as an object is constructed from the solidification material. The solidification substrate facilitates the creation of a substantially flat surface of solidification material that is exposed to the energy provided by a linear solidification device. The substantially flat surface improves the accuracy of the construction process. In certain embodiments, as described below, the solidification substrate is rocked to facilitate separation of the solidified material from the solidification substrate. In certain other embodiments, one or more stripping members are provided to separate the solidification substrate assembly from an object being constructed. In further embodiments, the solidification substrate is a flat or curved substrate that is translated with the linear solidification device as it passes through the solidifiable material.

The system is generally used to manufacture three-dimensional objects from a solidifiable material and rapid prototyping. A linear solidification device comprising a solidification energy source (such as a laser diode or a set of LEDs) creates a series of adjacent linear images on a solidifiable material that can vary according to the shape of the object being constructing as the device moves through the surface of the solidifiable material to selectively solidify it.

As discussed in this document, a solidifiable material is a material that, when subjected to energy, hardens totally or partially. This reaction to solidification or partial solidification can be used as the basis for building the three-dimensional object. Examples of a solidifiable material may include a polymerizable or crosslinkable material, a photopolymer, a photographic powder, a photographic paste or a photosensitive compound containing any kind of ceramic-based powder such as aluminum oxide or zirconium oxide or zirconium oxide stabilized with ytteria, a curable silicone composition, silica-based nanoparticles or nanocomposites. The solidifiable material may also include fillers. In addition, the solidifiable material can assume its final form (for example, after exposure to electromagnetic radiation) which can vary from semi-solids, solids, waxes and crystalline solids. In an embodiment of a photopolymer paste solidifiable material, a viscosity of between 10,000 cP (centipoise) and 150,000 cp (between 10 Pa and 150 Pa) is preferred.

When talking about a photopolymerizable, photocurable or solidifiable material, any material is understood, which possibly comprises a resin and optionally additional components, which is solidifiable by means of the supply of stimulating energy such as electromagnetic radiation. Suitably, a material that is polymerizable and / or crosslinkable (i.e. curable) by electromagnetic radiation (common wavelengths currently in use include UV radiation and / or visible light) can be used as such materials. In one example, a material comprising a resin formed from at least one ethylenically unsaturated compound (which includes but is not limited to monomers and polymers of (meth) acrylate) and / or at least one compound containing groups can be used epoxy Other suitable components of the solidifiable material include, for example, inorganic and / or organic fillers, coloring substances, viscosity control agents, etc., but are not limited thereto.

When photopolymers are used as the solidifiable material, a photoinitiator is usually provided. The photoinitiator absorbs the light and generates free radicals that initiate the polymerization and / or cross-linking process. Suitable types of photoinitiators include metallocenes, 1,2 di-ketones, acylphosphine oxides, benzyl dimethyl ketals, a-amino ketones and a-hydroxyketones. Examples of suitable metallocenes include Bis (eta 5-2, 4-cyclopenadien-1-yl) Bis [2,6-difluoro-3- (1 H-pyrrol-1-yl) phenyl] titanium, such as Irgacure 784 , which is supplied by Ciba Specialty chemicals. Examples of suitable 1,2-di-ketones include quinones such as camphorquinone. Examples of suitable acylphosphine oxides include bis acylphosphine oxide (BAPO), which is supplied under the name Irgacure 819, and monoacrylic phosphine oxide (MAPO) which is supplied under the name Darocur® TPO. Both Irgacure 819 and Darocur ® TPO are supplied by Ciba Specialty Chemicals. Examples of suitable benzyl dimethyl ketals include alpha, alpha-dimethoxy-alpha-phenylacetophenone, which is supplied under the name Irgacure 651. Suitable a-amino ketones include 2-benzyl-2- (dimethylamino) -1 - [4- (4- morpholinyl) phenyl] -1-butanone, which is supplied under the name Irgacure 369. Suitable a-hydroxyketones include 1-hydroxy-cyclohexyl-phenyl ketone, which is supplied under the name Irgacure 184 and a 50-50 mixture (in weight) of 1- hydroxycyclohexyl-phenyl ketone and benzophenone, which is supplied under the name Irgacure 500.

The linear solidification device can be configured in several ways. In some examples, the linear solidification device progressively exposes parts of solidifiable material to solidification energy in one direction (one scanning direction) while the device moves in another direction. In other examples, a solidification energy pattern is generally applied - or

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preferably substantially linear in a single exposure along one direction as the device moves in another direction. The solidification energy may comprise electromagnetic radiation. Electromagnetic radiation may include actinic light, visible or invisible light, UV radiation, IR radiation, electron beam radiation, X-ray radiation, laser radiation or the like. In addition, although each type of electromagnetic radiation in the electromagnetic spectrum in general can be described, the description is not limited to the specific examples provided. Those skilled in the art know that variations in the type of electromagnetic radiation and the methods for generating electromagnetic radiation can be determined based on the needs of the application.

With reference to FIG. 1-6, a first system 40 is represented to make a three-dimensional object. System 40 includes a solidification substrate assembly 62 (FIG. 2) and a linear solidification device 88 (FIG. 3-5C). The system 40 includes a housing 42 to support and contain the components of the system 40. The housing 42 includes a viewing window 44 that is movably arranged in an opening of the housing 49. The viewing window 44 allows users to observe an object while it is being built during an object creation operation. In the example of FIG. 1-6, the viewing window 44 is mounted on a hinge 60 (FIG. 2), allowing the window 44 to open and close pivotally about the longitudinal axis of the hinge 60, thus providing access to the object constructed a Once the construction operation is completed.

The housing 42 also includes a bottom compartment 52 (FIG. 2) to accommodate a photopolymer resin container 48. The photopolymer resin container 48 is mounted on a sliding support assembly 50 that allows the container 48 to be inserted and slide out of the lower compartment 52. The sliding support assembly 50 provides a means to add or remove photopolymer resin from the container 48 or to replace the container 48. The lower compartment door 46 (FIG. 1) secures removably the sliding support assembly 50 within the lower compartment 52.

The worktable assembly 55 comprises a worktable 56 and a solidification substrate assembly 62. The worktable 56 is disposed inside the housing 42 over the lower compartment 46 and includes the opening 54 (FIG. 2 ) through which the object construction platform 43 is disposed mobile. The latch 58 is provided to secure the solidification substrate assembly 62 to the worktable 56 during an object construction process.

The construction platform 43 is connected to an elevator assembly (not shown) that moves the construction platform 43 down to the resin container 48 during an object construction operation and upwards outside the resin container 48 once that an object construction operation is completed. As indicated in FIG. 2, the construction platform 43 has a resting position in which it rises above the worktable 56 to facilitate the extraction of finished objects, as well as the removal of any excess resin on the platform 43. In some examples Illustratively, the construction platform 43 stops at periodic intervals, and the linear solidification device 88 supplies solidification energy to the exposed solidification material on an exposed surface of solidifiable material with the construction platform 43 at rest. In other examples, the construction platform 43 moves continuously away from the worktable 56 as solidification energy is supplied to the solidifiable material.

With reference to FIG. 3, a solidification and object separation system is shown that includes a solidification substrate assembly 62 and a linear solidification device 88. The linear solidification device 88 progressively applies solidification energy to a solidifiable material in a first direction (direction y) as it moves in another direction (x direction) through the surface of a solidifiable material, such as a photo-curable resin (not shown in the figure) In preferred embodiments, the linear solidification device 88 includes a linear scanning device and the solidification energy is scanned in a scanning direction that defines a scanning axis (i.e., the y axis) while the linear solidification device 88 moves in the x direction. Preferably, the linear solidification device 88 does not move by itself in the direction and while this occurs. Sequential linear scans in the direction of the scan axis can be referred to here as "linear scan operations".

The linear solidification device 88 comprises a solidification energy source 90, a scanning device and a housing 96. In the embodiment represented in FIG. 3, the scanning device is a rotating energy deflector 92. In other examples of a linear solidification device 88, the scanning device is a laser scanning micro mirror that is used instead of the rotating energy deflector 92. Therefore , it should be understood at all times that a laser scanning micro mirror can be used instead of a rotating energy deflector 92 in the exemplary embodiments described herein.

Suitable laser scanning micro mirrors include magnetically driven MOEMS micro mirrors (microelectromechanical systems) supplied under the name LSCAN by Lemoptix SA of Switzerland. A linear scanning micro mirror comprises a silicon chip with a fixed part and a part of

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moving mirror The mirror is electrically or magnetically actuated to lean with respect to the fixed part to a degree that corresponds to the actuation signal. When the mirror is tilted, the solidification energy received is scanned by deflection from the tilting mirror. Therefore, the degree of inclination or angle of inclination corresponds to the position along the scan axis (y) in which the deviated solidification energy hits the surface of the solidifiable material.

In some preferred examples, and as shown in FIG. 3, a lens 98 is provided between the rotating energy deflector 92 and a lower surface of the housing 96 to focus the deflected solidification energy and transmit it to the solidifiable material. In the example of FIG. 3, the solidifiable material is below and in contact with the rigid or semi-rigid solidification substrate 68. In the example of FIG. 3, the lens 98 is preferably a flat field lens. In some examples, the lens 98 is a flat field lens that is transparent to violet and ultraviolet radiation. In additional examples, the lens 98 also has a longer focal length at the ends of the lens relative to the center (referring to the scanning direction of the axis and along which the length of the lens is oriented) to compensate for the different solidification energy beam travel distances from the rotating energy deflector 92 to the solidifiable material. In certain implementations, the lens 98 includes an anti-reflective coating such that the coated lens transmits at least 90%, preferably at least 92%, and more preferably at least 95% of the incident light having a varying wavelength. from about 380 nm to about 420 nm In one example, the lens 98 transmits at least about 95% of the incident light having a wavelength of about 405 nm. Suitable coatings include single-layer magnesium difluoride (MgF2) coatings, including ARSL0001 MgF2 coatings supplied by Siltint Industries of the United Kingdom.

The housing 96 also includes a substantially linear opening 100 (for example, a slit) through which light is projected to the rigid or semi-rigid solidification substrate 68 and onto the solidifiable material.

FIG. 3 and 4 show the housing 96 in the first and second positions, respectively, along the length (x axis) of the solidification substrate assembly 62. In the embodiment of FIG. 3-4, the housing 96 moves in the x direction, but not in the y direction. The engine 76 is provided to drive the housing 96 through the surface of the rigid or semi-rigid solidification substrate 68 (and the surface of the solidifiable material below) from one end of the solidification substrate assembly 62 to the other in the direction x. In some examples, the motor 76 is a servo motor or a stepper motor. In any case, the motor 76 has an associated motor movement parameter that corresponds to a degree of linear movement of the linear solidification device 88 in the direction of the x-axis. In certain cases, the parameter is a number of motor steps corresponding to a particular linear distance that the linear solidification device 88 moves in the direction of the x-axis. As the housing 96 moves in the x direction (the longitudinal direction of the solidification substrate assembly 62), the solidification energy source 90 and the rotating energy deflector 92 move therewith. During this movement, the solidification energy, preferably the laser light, is periodically or continuously projected from the solidification energy source 90 to the rotating energy deflector 92. In a preferred embodiment, the solidification energy source 90 is a laser diode that emits light in the range of 380 nm to 420 nm. A range of 390 nm to 410 nm is preferred, and a range of 400 nm to about 410 nm is more preferred. The laser power is preferably at least about 300 mW, more preferably at least about 400 mW, and even more preferably, at least about 450 mW. At the same time, the laser power is preferably not more than about 700 mW, more preferably not more than about 600 mW, and even more preferably not more than about 550 mW. In one example, a 500 mW and 405 nm blue light laser is used. Suitable blue light laser diodes include 405 nm and 500 mW laser diodes supplied by Sanyo.

The rotating energy deflector 92 deflects the solidification energy that strikes it towards the fixed field lens 98. The rotating energy deflector 92 preferably rotates in a rotation plane while the linear solidification device 88 moves in the direction of the length (x axis). In some examples, the plane of rotation is substantially perpendicular to the direction in which the linear solidification device 88 moves (ie, the plane of rotation is the y-z plane shown in FIGS. 3-4). In some examples, the rotating energy deflector 92 rotates at a substantially constant rotation speed. In other examples, the linear solidification device 88 moves at a substantially constant speed in the direction of the length (x axis). In additional examples, the rotating energy deflector 92 rotates at a substantially constant rotation speed and the linear solidification device 88 moves in the direction of length (x-axis) at a substantially constant speed.

When the solidification energy source 90 is a light source, the rotating energy deflector 92 is preferably a rotating light deflector capable of deflecting visible or UV light. In an exemplary embodiment, the rotating energy deflector 92 is a polygonal mirror having one or more facets 94a, b, c, etc., defined around its perimeter. In the example of FIG. 3, the rotating energy deflector 92 is a hexagonal mirror that has facets 94a to 94f. Each facet 94a-94f has at least one rotation position, and preferably several, in which it will be in optical communication with the source

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of solidification energy 90 to receive the projected light from there. While the rotating energy deflector 92 rotates, the solidification energy (for example, visible or ultraviolet light) will be defined along the length of each facet 94a-f successively. At any time, one of the facets 94a-94f will receive and divert solidification energy. As the facet changes its position of rotation, the angle of incidence of the solidification energy with respect to the facet will change, altering the angle of deflection and, therefore, the location of the axis and at which the solidification energy defined hits solidification substrate 68 and solidifiable material beneath it. Thus, each rotating position of the rotating energy deflector 92 corresponds to a position along the scan axis (y) in which solidification energy can be projected at a given time. However, for a given number of rotating energy deflecting facets F, there will be rotating positions F each corresponding to a particular position along the direction of the scanning axis. As will be described in greater detail below, one or more controllers or microcontrollers can be provided to regulate the activation and deactivation of the construction platform 43, the solidification energy source 90, the rotating energy deflector 92 and a motor that it passes through the linear solidification device 88 through the solidifiable material.

In some examples, the maximum scan length in the axis direction and will correspond to the full length of an individual facet 94a-94f. That is, as the light progressively affects the entire length of any facet 94a-94f, the deflected light will correspondingly complete a full scan length in the y-axis direction. The number of facets 94a, 94b, etc. in the rotating energy deflector 92 it will correspond to the number of axis scans and that are performed for a complete rotation of the rotating energy deflector 92. In the case of a hexagonal mirror, six axis scans will be performed and for each complete rotation of the deflector of rotating energy 92. For rotating energy baffles that maintain a constant direction of rotation (for example, clockwise or counterclockwise), the scans will be unidirectional along the y axis. In other words, as light transitions from one facet 94a to another 94b, the scan will return to its initial position on the y-axis, instead of scanning backwards in the opposite direction. However, other rotary energy deflector configurations can be used, including those in which the rotary energy deflector 92 rotates in two directions of rotation to produce a "round-trip" sweep in the y-axis direction.

It is useful to use the term "building envelope" to describe the maximum length (in the x direction) and the maximum width (in the y direction) in which solidification energy can be supplied to the solidifiable material. In the embodiment of FIG. 3-4, the area of the construction envelope will usually be smaller than the area of the solidification substrate 68 or the area defined by the exposed and upwardly oriented surface of the solidifiable material beneath it. In the example of FIG. 3, the construction envelope will comprise a dimension x (length) that is less than or equal to the total distance that the solidification energy source 90 and the rotating energy deflector 92 can cross in the x direction. In some cases, the dimension and (width) of the construction envelope may be somewhat longer than the length of the lens 98 and the housing opening 100 because the light projected from the flat field lens 98 and through the aperture From the housing 100, the direction of the shaft can be projected and at an angle of incidence not orthogonal with respect to the exposed surface of the solidifiable material.

FIG. 16 (b) and (c) represent a top view of a region of solidifiable material that includes a construction envelope 342. The construction envelope defines the maximum area of solidification and, therefore, the maximum three-dimensional object in the plane xy. As shown in FIG. 16 (b) and 16 (c), in certain cases the linear solidification device 88 is movable in the direction of the x-axis along a total distance that is equal to the sum of a distance of length L of the construction envelope 342 and two travel distances, 5l and 5r. The travel distances 5l and 5r respectively represent the distance from the left end of travel (EOT) position of the linear solidification device 88 to the construction envelope limit of the left side 343 and the distance from the EOT position of the right side to the limit The right side construction envelope 345. In some examples, the travel distances, 5l and 5r are provided to ensure that the linear solidification device 88 has time to reach a substantially constant speed in the direction of the x-axis before it begins any solidification of solidifiable material (that is, before the envelope 342 is constructed). In some examples, the movement of the linear solidification device 88 at a constant speed of the x-axis avoids the need to directly measure the position of the x-axis at any given time because it allows a motor movement parameter for the motor 76 to provide a Indirect indication of the position of the x-axis In a particular example suitable for servo and stepper motors, the motor movement parameter is a number of motor phases. In some examples, 5l and 5r are the same.

In some examples, as the energy deflector 92 rotates, the solidification energy source 90 will selectively project the light according to the data representing the object being constructed. At a certain location in the direction of the x-axis, some locations of the y-axis can solidify and others cannot, depending on the shape of the object being constructed.

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One way of selectively projecting light to the solidifiable material is to selectively activate the solidifiable energy source 90 depending on the location of the x-axis of the linear solidification device and the rotational position of the facet 94a-f which is in optical communication with the energy source. of solidification 90. Although each facet 94a-94f will have a full range of locations along its length in which solidification energy can be received from the solidification energy source 90, it will not necessarily be the case that each facet location receive solidification energy during any individual scan performed by that facet. Thus, by coordinating (directly or indirectly) the activation of the solidification energy source with the rotational position of a given facet 94a-94f, the solidification energy can be selectively provided to only those locations along the axis and where You want solidification.

The number of linear scans that can be performed within a certain linear distance along the direction of the x-axis can depend on several variables, including the rotational speed of the rotating energy deflector 92, the number of facets F in the deflector of rotating energy 92, and movement speed of the linear solidification device 88 along the direction of the x-axis. In general, as the movement speed of the linear solidification device 88 increases in the direction of the x axis, the number of linear scans per unit length of the x axis decreases. However, as the number of facets in the rotating energy deflector 92 increases or when the rotational speed of the rotating energy deflector 92 increases, the number of linear scans per unit length of the x-axis increases.

Therefore, for a given construction envelope distance L in units such as millimeters, the maximum number of line scanning operations that can be performed can be calculated as follows:

(1) Nmax = (L / S) * (RPM / 60) * F

where,

Nmax = maximum number of line scanning operations in the x-axis direction within the construction envelope;

L = desired length of the construction envelope in the direction of the x-axis (mm);

S = speed of movement of the solidification energy source in the direction of the x-axis (mm / sec);

RPM = rotational frequency of the rotating energy deflector (revolutions / minute); Y

F = number of facets in the rotating energy deflector.

Each linear scan can be assigned a linear scan index n (which can also be called a string index when sets of data strings are used as object layer data) ranging from a value of 0 to Nmax- one. Equation (1) can also be used to calculate a real number of line scanning operations necessary for a given part length in the direction of the x-axis. In that case, L would be the desired length of the part in the x-axis direction and Nmax would be replaced by N, which would represent the total number of line scanning operations used to form the part.

When the linear solidification device moves at a constant speed S in the direction of the x-axis, a motor movement parameter such as a number of motor stages for the motor 76 can be correlated with the envelope length L and used for Define a variable W that is equal to a number of motor steps / L. The microcontroller unit can use the number of motor stages to indirectly determine the number of a linear scan position (or chain index as further described herein) of the linear solidification device within the construction envelope according to with the following equation:

(2) scan index n = ((number of steps from the limit) / (W) (S)) * (RPM / 60) * F

In equation (2), the number of steps from the limit refers to the number of motor steps counted starting at the construction envelope limit 343 and moving from left to right or starting at the construction envelope limit 345 and moving from right to left. A particular three-dimensional object layer having a length can be formed by a series of linear scans performed within the construction envelope 342.

In some examples, the host will assign scan index numbers or string index numbers by scaling the part to the size of the construction envelope and assigning a scan index number n based on the total number of possible Nmax scans in the envelope of construction 342. The scan index numbers n will be correlated with a series of motor phases as set forth in equation (2). This relationship depends, in part, on the accuracy of the value W which is the ratio of the number

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of phases required for the linear solidification device 88 to cross the length of the construction envelope L (FIG. 16 (b)) divided by L. As explained below, in some cases, W may deviate from the value predicted by the geometry of the mechanical devices used to move the linear solidification device 88 (i.e., the value predicted by the transmission ratio for the engine 76, the rotation speed of the engine 76, and the pulley diameter of the pulleys 82a and 82b). In that case, it may be desirable to adjust the value of W. The methods for adjusting the value of W are described below.

In another example, a flexible flat film mask is provided between the linear solidification device 88 and the rigid or semi-rigid solidification substrate 68. The flexible flat film mask has a plurality of transparent imaging elements that define a matrix. Each image element can be selectively made transparent or opaque by providing power. Examples of such flexible flat film masks include transparent organic light emitting diode (OLED) screens and liquid crystal display (LCD) screens. The matrix is configured in a plurality of rows (1-n) arranged along the length (x axis) direction of the solidification substrate assembly. Each row defines a location of the x-axis and has a plurality of elements along the direction of the axis and which can be made selectively transparent or opaque to allow the energy of the solidification energy source 90 to pass through them. Therefore, at a specific location of the x-axis, the specific members of a row that are activated to allow the transmission of energy will dictate which parts of the solidifiable material in the direction of the axis and will receive solidification energy while continuing to continuously supply energy from the solidification energy source 90 to the rotating energy deflector 92.

As previously indicated, the systems for making a three-dimensional object described herein may include a control unit, such as a microcontroller or microcontroller unit, which contains programs stored locally and executed to activate the motors 76, 118 and the moving construction platform 43, as well as to selectively activate the solidification energy source 90. In some examples, the systems include a host computer that processes data from three-dimensional objects in a format recognized by the microcontroller unit and then transmits the data to the microcontroller for use by programs stored and executed locally from the microcontroller unit. As used herein, the term "microcontroller" refers to a high performance programmable computer memory system used for special tasks. In some examples, the microcontrollers described in this document include an integrated circuit chip that has a microprocessor, a read-only memory (ROM), interfaces for peripheral devices, timers, analog to digital converters and digital to analog converters, and possibly other units functional.

In some examples, a linear solidification controller (not shown) selectively activates and deactivates the linear solidification device 88, at least in part, depending on the position of the linear solidification device 88 in the length direction (axis x). The position can be detected directly or can be determined indirectly by other variables (for example, a number of motor stages). In an implementation described below, an end-of-travel sensor 346 (Figures 16 (b) and (c)) is used together with a motor movement parameter to indirectly determine the position of the x-axis.

In one implementation, the linear solidification controller is a microcontroller or solidification energy source controller (not shown) that is operatively connected to the solidification energy source 90 to change the activation state of the energy source of solidification 90 by activating and deactivating it selectively. In additional examples, the controller selectively activates the solidification energy source, at least in part, based on the shape information about the three-dimensional object being constructed. In additional examples, the controller selectively activates the solidification energy source based on the position of the linear solidification device 88 in the direction of length (x-axis) (or based on another variable that correlates with the position such as a number of motor phases for motor 76) and is based on shape information about the object being constructed, which varies with the position of the x-axis. On a given exposed surface of solidifiable material, the x, and specific locations that will receive the solidification energy will depend on the profile of the axis and the object being constructed at the determined location of the x-axis of the solidification energy source 90 and the rotating energy baffle 92. In additional examples, the linear solidification controller selectively activates the imaging elements on a flat film mask to selectively solidify the desired locations in the solidifiable material. In other examples, a laser scanning micro mirror selectively deflects solidification energy in a linear pattern to perform a linear scan operation.

In some examples, information on the shape of the object being constructed is provided as three-dimensional information on the shape of the object that mathematically defines the shape of the object in three-dimensional space. The three-dimensional object data is laminated or subdivided into object layer data preferably along a dimension corresponding to a construction axis. The construction axis refers to an axis along which an object is progressively constructed and in the examples

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described in this document is commonly referred to as the "z axis". The object layer data may comprise information that mathematically defines the shape of the object in a plane orthogonal to the construction axis. Therefore, in an example where the construction axis is called the z axis, each object data layer set may comprise x and y coordinates that define the shape of the cross section of the object at a given position on the z axis. Exemplary methods for providing and using object data to carry out the solidification process are described below.

As previously mentioned, the engine 76 is provided to move the housing 96 through the surface of the solidifiable material in the direction of the x-axis. An exemplary apparatus for providing translation is depicted in FIG. 3 and 4. According to the figures, the housing 96 is connected to two cam follower assemblies 104a and 104b separated along the width (y-axis direction) of the solidification substrate assembly 62. The motor 76 rotates the shaft 78, which is connected at its ends 80a and 80b to the respective timing belts 86a and 86b. Each timing belt 86a and 86b is connected to a corresponding pulley, 82a and 82b, which is rotatably mounted on a corresponding support 83a and 83b mounted on the stationary frame 64 of the solidification substrate assembly 62.

The cam follower assemblies 104a and 104b are each connected to a corresponding one of the timing belts 86a and 86b through the corresponding belt connectors 114a and 114b. The cam follower assemblies 104a and 104b are also connected to the corresponding linear bearings 110a and 110b which slidably engage the corresponding linear sliders or rails 112a and 112b. The linear sliders 112a and 112b are attached to the stationary frame 64 and are separated from each other in the direction of the width (y-axis) of the solidification substrate assembly 62. When the motor 76 receives power, the shaft 78 rotates around its longitudinal axis. , causing timing belts 86a and 86b to circulate in an endless loop. The circulation of the toothed belts 86a and 86b causes the cam follower assemblies 104a and 104b to move in the direction of the length (x axis) of the solidification substrate assembly 62, which in turn moves the housing 96 of the device linear solidification in the direction of length (x axis). Therefore, the concurrent activation of the motor 76, the rotating energy deflector 92 and the solidification energy source 90, allows the solidification energy to be scanned in the width (y-axis) direction along an exposed surface of the material solidifiable at the same time as the translation of the solidification energy source 90 and the rotating energy deflector 92 in the direction of the length (x-axis).

A more detailed view of the linear solidification device 88 is provided in FIG. 5A and 5B, which show opposite sides of the device 88. The housing 96 is a generally polygonal structure. As shown in the figures, the housing 96 has an open face, but the face may be closed. The rotating energy baffle 92 is separated from the solidification energy source 90 in both the height (z axis) and width (y axis) directions, and may also be slightly offset from the solidification energy source 90 in the length direction (x axis). The rotating energy baffle 92 is rotatably mounted in the housing 96 to rotate substantially within a plane that can preferably be oriented substantially perpendicular to the direction of the length (x-axis) (i.e., the y-z plane). The solidification energy source port 116 is provided to mount a solidification energy source (eg, a laser diode) so that it is in optical communication with at least one facet 94a-94f of the rotating energy deflector 92 to the time. As indicated above, the lens 98 is separated and below the rotating energy deflector 92 in the height direction (z axis) and is located above the light opening 100 of the housing.

The motor 118 is mounted on a rear surface of the housing 96 and is operatively connected to the rotating energy deflector 92. The motor 118 is connected to a power source (not shown). When the motor 118 receives power, the rotating energy deflector 92 rotates in the yz plane, placing the various facets 94a-94f sequentially in optical communication with the solidification energy source 90. A control unit (which does not shown) to selectively supply power to motor 118, solidification power source 90 and / or motor 76. One or both motors 76 and 118 may be stepper motors or servomotors. In some examples, one or both motors 76 and 118 are driven by continuous energy pulses. In the case of the motor 118, in certain preferred embodiments, it is driven by continuous energy pulses so that the timing of each pulse corresponds to a fixed rotation position of a facet 94 (a) - (f) of the deflector of rotating energy 92. When the motor receives pulses, each of the facets 94 (a) - (f) will sequentially enter optical communication with the solidification energy source 90, and the particular facet that is in optical communication with the source of solidification energy 90 will have a fixed rotation position corresponding to the pulse time.

In certain implementations, the rotational position of the rotating energy deflector 92 may repeatedly correspond to the timing of each motor energy pulse without the operator knowing it. The fixed association of the motor energy pulse and the rotational position of the facets 92a-92f allows to use the motor pulse timing to synchronize the transmission of a synchronization solidification energy signal of the solidification energy source 90 so that an energy signal is emitted

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of synchronization solidification for each facet 94 (a) - (f) in a defined rotation position while in optical communication with the solidification energy source 90.

In certain implementations, it is desirable to provide a scan speed of the axis and (i.e., a speed at which solidification energy moves along the exposed surface of the solidifiable material) that is significantly greater than the velocity of the xa axis which linear solidification device 88 moves. Providing this disparity in the y-axis velocities of the x-axis helps to better ensure that the scanned energy pattern is linear and orthogonal to the direction of the x-axis, thus reducing the probability of object distortion. In some examples, the scanning speed in the y-axis direction is at least about 1000 times, preferably at least about 1500 times, more preferably at least about 2000 times, and even more preferably at least about 2200 times the movement speed of the linear solidification device 88 in the direction of the x axis. In one example, the linear solidification device 88 moves at a speed of about 1 inch / second in the direction of the x-axis and the scan speed of the y-axis is about 2400 inches / second. Increasing the scanning speed relative to the movement speed of the linear solidification device 88 in the direction of the x-axis increases the resolution of the scanning process by increasing the number of scan lines per unit length in the direction of the x-axis.

The scanning speed (in number of scans per unit of time) to which solidification energy is progressively applied to selected areas of a solidifiable resin in the direction of width (y axis) of the solidification substrate assembly 62 corresponds to the speed of rotation of the rotating energy deflector 92 multiplied by the number of facets 94a-f. In some examples, the rotation speed is from about 1000 to about 10,000 rpm, preferably from about 2000 to about 8000 rpm, and more preferably from about 3000 to about 5000 rpm.

With reference to FIG. 5C, an alternative embodiment of the linear solidification device 88 of FIG. 5A and B. In FIG. 5C, the housing 96 is removed. As shown in the figure, the solidification energy source 90 is in optical communication with a facet 94 (a) - (f) of the rotating energy deflector 92 at any time while the deflector of rotating energy 92 rotates in the yz plane (ie, the plane orthogonal to the direction of movement of the linear solidification device 88). In this embodiment, one or more solidification energy focusing devices are provided between the solidification energy source 90 and the rotating energy deflector 92. In the example of FIG. 5C, the one or more focusing devices comprise a collimator 320 and a cylindrical lens 322.

The collimator 320 is provided between the solidification energy source 90 and the cylindrical lens 322. The cylindrical lens 322 is provided between the collimator 320 and the rotating energy deflector 92. The collimator 320 is also a focusing lens and creates a beam round shape The cylindrical lens 322 stretches the beam round in a more linear manner to allow the beam to decrease the area of impact against the rotating energy deflector 92 and more precisely adjust the beam within the dimensions of a particular facet 94 (a )-(F). Therefore, the solidification energy transmitted from the solidification energy source 90 passes through the first collimator 320 and the cylindrical lens 322 seconds before reaching a particular facet 94 (a) - (f) of the rotating energy deflector 92 .

In some preferred examples, collimator 320 and / or cylindrical lens 322 transmit at least 90%, preferably at least 92%, and more preferably at least 95% of the incident light having a wavelength that varies from approximately 380 nm to approximately 420 nm. In one example, collimator 320 and cylindrical lens 322 transmit at least about 95% of the incident light having a wavelength of approximately 405 nm. In the same or other examples, the solidification energy source 90 comprises a laser diode having a beam divergence of at least about five (5) milliadianes, more preferably at least about six (6) milliradianes, and more preferably at least approximately 6.5 miliradianes. At the same time or in other examples, the beam divergence is not more than about nine (9) milliadianes, preferably not more than approximately eight (8) milliradianes, and even more preferably no more than approximately 7.5 milliradianes. In one example, the divergence is approximately 7 milliradianes. The collimator 320 is preferably configured with a focal length sufficient to collimate the light having the previous beam divergence values. Collimator 320 is preferably configured to receive incident laser light that has a "butterfly" shape and converts it into a round beam for transmission to cylindrical lens 322.

In some examples, collimator 320 has an effective focal length ranging from about 4.0 mm to about 4.1 mm, preferably from about 4.0 mm to about 4.5 mm, and more preferably from about 4.01 mm to about 4.03 mm. In one example, collimator 320 is an aspherical molded glass collimator lens having an effective focal length of approximately 4.02 mm. One such collimator 320 is an asymmetric molded glass collimator lens coated with Geltech ™ antireflective supplied as part number 671TME-405 by

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Thorlabs, Inc. of Newton, New Jersey. This collimator is made of ECO-550 glass, has an effective focal length of 4.02 mm and has a numerical aperture of 0.60.

In some examples, collimator 320 and / or cylindrical lens 322 are optimized based on the specific wavelength and divergence characteristics of the solidification energy source 90. In one example, collimator 320 and / or cylindrical lens 322 are formed from a borosilicate glass such as BK-7 optical glass. In some preferred examples, collimator 320 and / or cylindrical lens 322 are coated with an anti-reflective coating such that coated collimator 320 and coated cylindrical lens 322 transmit at least 90%, preferably at least 92% and more preferably at least 95% of the incident light having a wavelength that varies from about 380 nm to about 420 nm. Suitable anti-reflective coatings include magnesium difluoride (MgF2) coatings such as the MgF2 coating ARSL0001 supplied by Siltint Industries of the United Kingdom.

In some examples of a linear solidification device 88, solidification energy defines a point (which may or may not be circular) at the point of impact on the solidifiable material. The angle of incidence between the solidification energy and the solidifiable material will vary with the rotational position of a given facet 94 (a) - (f) in relation to the solidification energy source 90. The dimensions and shape of the point will also tend to vary according to the angle of incidence. In some cases, this variation in spot size and / or point dimensions may produce uneven solidification patterns and degrade the accuracy of the object's construction process. Thus, in some examples, one or more lenses are provided between the rotating energy deflector 92 and the solidifiable material to increase the uniformity of the size and / or dimensions of the point as the rotational position of the rotating energy deflector 92 changes. In some examples, the one or more lenses is a flat field lens 98 (FIG. 5A and 5B). In other examples (FIG. 5C), the one or more lenses is an F-Theta lens (328 or 330). In other examples, and as also shown in FIG. 5C, the one or more lenses are a pair of F-Theta 328 and 330 lenses. F-Theta 328 and 330 lenses are separated from each other and the rotating energy deflector 92 along the direction of the z-axis (is that is, the axis that is perpendicular to the scanning direction and the direction of movement of the linear solidification device 88) The first F-Theta 328 lens is positioned between the second F-Theta 330 lens and the rotating energy deflector 92. The second F-Theta 330 lens is positioned between the first F-Theta 328 lens and the solidifiable material (as well as between the first F-Theta 328 lens and the light aperture 100, which is not shown in FIG. 5C-D) .

The first F-Theta 328 lens includes an incident face 334 and a transmitting face 336. The incident face 334 receives solidification energy deflected from the rotating energy deflector 92. The transmitting face 336 transmits solidification energy from the first F-Theta 328 lens to the second F-Theta 330 lens. Similarly, the second F-Theta 330 lens includes the incident face 338 and the transmitting face 340. The incident face 338 receives solidification energy transmitted from the transmitting face 336 of the first lens F -Theta 338, and the transmitting face 340 transmits solidification energy from the second F-Theta 330 lens to the light aperture of the housing 100 (not shown in FIG. 5C) and to the solidifiable material.

In certain implementations of the linear solidification device of FIG. 5C, the first F-Theta 328 lens has a refractive index that is smaller than that of the second F-Theta 330 lens. The relative difference in refractive indices helps reduce the losses by laser beam scattering. At the same time or in other implementations, the radius of curvature of the first transmitting lens face F-Theta 336 is smaller than the radius of curvature of the second transmitting lens lens F-Theta 340. The suitable pairs of F-Theta lenses They are commercially available and include F-Theta lenses supplied by Konica Minolta and HP. In certain embodiments, the F-Theta 328 and 330 lenses are preferably coated with an anti-reflective coating. The anti-reflective coating is used to maximize the amount of selected solidification energy wavelengths that are transmitted through the F-Theta 328 and 330 lenses. In one example, the anti-reflective coating allows the F-Theta lenses coated 328 and 330 transmit more than 90 percent of the incident solidification energy having a wavelength between approximately 325 nm and 420 nm, in which preferably more than 90 percent of the incident solidification energy has a wavelength between approximately 380 nm and about 420 nm, more preferably greater than about 92 percent of the incident solidification energy having a wavelength between about 380 nm and about 420 nm, and even more preferably more than 95 percent of the incident solidification energy that It has a wavelength between approximately 380 nm and approximately 420 nm. In a specific example, the coated F-theta lenses transmit at least about 95% of the incident light having a wavelength of approximately 405 nm (i.e., blue laser light). In other preferred embodiments, collimator 320 and cylindrical lens 322 are also coated with the same anti-reflective coating. Suitable anti-reflective coatings include magnesium difluoride (MgF2) coatings such as the ARSL001 coating supplied by Siltint Industries of the United Kingdom.

In some examples, the linear solidification device 88 may comprise multiple sources of solidification energy. In some implementations, the linear solidification device 88 may include multiple sources of solidification energy that provide solidification energy thereof.

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wavelength, and the device 88 can transmit a single beam of solidification energy to the solidifiable material. In other implementations, device 88 may include solidification energy sources of different wavelengths and selectively transmit solidification energy of only one of the wavelengths to a solidifiable material. This implementation can be particularly useful when building a three-dimensional object using multiple solidifiable materials each of which solidifies in response to the solidification energy of different wavelengths (for example, because its photoinitiators are activated by different wavelengths of solidification energy).

With reference to FIG. 5D, an alternative version of the linear solidification device 88 (with the housing removed) is schematically represented. The linear solidification device 88 is the same as that shown in FIG. 5C with two exceptions. First, the linear solidification device 88 of FIG. 5D includes two sources of solidification energy 90a and 90b. In the specific embodiment of FIG. 5D, solidification energy sources 90a and 90b transmit solidification energy of substantially the same wavelength. In some cases, the use of said multiple sources of solidification energy 90a, 90b is desirable to increase the power of the solidification energy transmitted to the solidifiable material. The power of the solidification energy can affect the solidification speed, which in turn can limit the maximum travel speed of the linear solidification device 88 in the direction of the x-axis. To solidify, for example, a given volume of a solidifiable resin, the volume must receive sufficient solidification energy (for example, in joules). The solidification energy received by a given volume of solidifiable material is a function of the power (for example, in watts) of the solidification energy and the exposure time of the volume of solidifiable material. As a result, as the power is reduced, the travel speed of the solidification energy device 88 must be reduced to ensure that sufficient solidification energy is received at each location along the direction of travel (i.e., x axis ) of the solidification energy device 88. In other words, at a desired solidification depth in the direction of the construction axis (z axis), increasing the power of the solidification energy increases the speed at which the energy can be traversed. linear solidification device 88 in the direction of the x-axis, and therefore, the speed of an object construction process

The second difference between solidification energy devices 88 of FIG. 5C and 5D is the inclusion of prisms 321 a and 321 b in FIG. 5 D. The solidification energy device 88 of FIG. 5D is intended to combine the solidification energy of both sources 90a and 90b in a single beam for administration to the solidifiable material. The individual beam preferably has a power that is at least 1.5 times, preferably at least 1.7 times, and more preferably at least 1.95 times the average power of the individual solidification energy sources 90a and 90b. Each solidification energy source 90a and 90b transmits its respective solidification energy to a respective prism 321a and 321b. Prisms 321a and 321b receive incident solidification energy at a first angle and divert energy to produce beams of solidification energy transmitted at a second (different) angle that allows individual beams to combine into a single beam. It is believed that the individual beams are combined in front of the cylindrical lens 322, after which the solidification energy is received by the rotating energy deflector 92 and finally transmitted to the solidifiable material in the same manner previously described with respect to the FIG. 5C.

As mentioned above, the linear solidification device 88 of FIG. 5C and 5D also includes a solidification energy sensor 324, which can be an optical sensor. Suitable optical sensors include photodiodes. An example of a photodiode that can be used is a 404 nm and 500 mW photodiode supplied by Opnext with part number HL40023MG.

The solidification energy sensor 324 generates a signal upon receipt of the solidification energy. The mirror 332 is provided and is in optical communication with the rotating energy deflector 92 so that when each facet of the rotating energy deflector 92 receives solidification energy from the solidification energy source 90 while in a particular rotational position (or range of positions) in the yz plane, and the energy will be defined towards the mirror 332 (as shown in the dotted lines). Similarly, when the scanning device used in the linear solidification device 88 is a linear scanning micro mirror, an inclination angle or range of particular inclination angles will cause the received solidification energy to be diverted to the mirror 332. Solidification energy is then reflected outside the mirror 332 along a path that is substantially parallel to the scan axis (y axis) between the first F-Theta lens 328 and the second F-Theta lens 330 to the sensor 324. The sensor 324 may be operatively connected to a computer to which it will transmit the signal generated upon receiving solidification energy. The signal can be stored as data and / or used in programs associated with a solidification power source controller (not shown). An example of a line scan synchronization method that uses the generated sensor signal is described below.

In some examples, sensor 324 is used to determine the beginning of a line scan operation along the direction of the scan axis (y axis). However, in certain cases using the solidification energy sources described herein, the intensity of the solidification energy transmitted by the solidification energy source 90 may be greater than desired,

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thus reducing the sensitivity of the sensor 324 due, at least in part, to the presence of scattered light and ambient light. As a result, in some implementations a filter 326 is provided between the sensor 324 and the mirror 332 along the solidification energy travel path from the mirror 332 to the sensor 324. The filter 326 preferably reduces the radiation intensity. electromagnetic received by sensor 324 without appreciably altering its wavelength or length. Therefore, in one example, filter 326 is a neutral density filter. One such suitable neutral density filter is a 16x neutral density filter supplied by Samy's Camera of Los Angeles, California, with part number HDVND58. In some implementations, sensor 324 is used to synchronize a timer that serves as a reference for linear scanning operations. In such cases, exposure of sensor 324 to scattered or ambient light may cause synchronization errors. Therefore, filter 326 is preferably configured to ensure that sensor 324 only receives direct solidification energy from solidification energy source 90.

With reference again to FIG. 16 (b), in certain implementations, the linear solidification device 88 is positioned within the construction envelope 342 so that the mirror 332 is located immediately close to the construction envelope limit of the scan axis 344. In such implementations, solidification energy reception by sensor 324 (FIG. 5C) indicates that a line scan operation can begin immediately afterwards because if solidification energy source 90 remains activated and if rotational energy deflector 92 continues to rotate, the Solidification energy will be transmitted to the solidifiable material at the boundary 344 of the scan shaft construction envelope immediately after it is transmitted to the mirror 332. Therefore, the sensor 324 can be used to indicate the start of a line scan operation. for each facet 94 (a) -94 (f). As mentioned above, when the solidification energy source 90 remains activated while the rotating energy baffle 92 completes a single revolution, several linear scanning operations will be completed in the direction of the scanning axis that is equal to the number of the facets 94 (a) - (f) of the rotating energy deflector 92.

In those cases where the sensor 324 is used to indicate the beginning of a line scan operation, it is useful to briefly activate the solidification energy source 90 at a specific time when the transmitted solidification energy will be received by the mirror 332. The brief activation of the solidification energy source can be coordinated or synchronized with an activation signal sent to the scanning device used in the linear solidification device 88. For example, and as mentioned above, in certain cases, the motor 118 receives energy from a constant frequency pulse, whose time corresponds to a fixed rotation position for the particular facet 94 (a) - (f) which is in optical communication with the solidification energy source 90. Therefore Through a trial and error process, a delay time between the leading or trailing edge of the impulses can be determined of the motor and the reception of solidification energy by the sensor 324. More specifically, the solidification energy source 90 can be selectively activated several times relative to the leading or trailing edge of the pulse to determine what delay time results in the generation of a solidification energy sensor signal by sensor 324. In a preferred embodiment, solidification energy source 90 is activated at or within a specific time following the trailing edge of the energy pulse used to activate the motor 118.

In some examples, it is preferable to dynamically adjust or calibrate the timing of the synchronization energy pulses. According to such examples, the synchronization energy pulses are activated in a dynamically calibrated time with respect to an internal microprocessor clock (ie, in the microcontroller) without linking the synchronization energy pulses to the drive pulses sent to the motor 118 for rotating the rotating energy deflector 92. An implementation of the dynamic calibration of the synchronization energy pulse timing is as follows: when the motor of the rotating energy deflector 118 is first activated during a construction process of pieces, one or more test synchronization pulses are performed by a program resident in the microcontroller that activates the solidification power source 90 in one or more test times with respect to the microprocessor clock. The initial test time will be selected based on a delay time relative to the drive pulses sent to the motor 118 which is believed to cause the transmitted solidification energy to hit the sensor 324. The test times are adjusted progressively until it is completed. Dynamic calibration of synchronization energy pulses. The program resident in the microcontroller compares the time that the microcontroller sends an output signal to activate the solidification energy source 90 until the moment when the sensor 324 indicates that solidification energy has been received. The program adjusts the timing of the output signal (relative to the CPU clock) sent to the solidification power source 90 as soon as possible, which results in the transmission of a signal from the synchronization sensor 324, since this time indicates that the solidification energy has been transmitted as close as possible to the time in which the solidification energy comes into contact with the sensor 324. Next, the final time of the synchronization energy pulses determined by this process setting is saved and used in subsequent synchronization operations. As previously indicated, the pulse time is defined in relation to the cycles of a CPU clock in the microprocessor to ensure that they are repeatable. In some cases, the use of this dynamic adjustment process to reach synchronization of the synchronization energy pulse is more accurate than

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synchronize the synchronization energy pulses based on a fixed time relative to the pulses of the motor 118, including because in certain cases the relationship between the pulses of the motor 118 and the rotational position of the rotating energy deflector 92 may fluctuate or vary despite the fact that the rotating energy deflector 92 rotates at a substantially constant frequency.

The activation of the solidification energy source 90 in relation to the pulses sent to the motor 118 according to an example is shown in FIG. 24. Waveform 1100 represents the output signal of the microcontroller sent to the motor 118 to rotate the mirror 92. Waveform 1102 represents the output signal of the microcontroller sent to the solidification power source 90 to toggle the source of solidification energy of the activation state. The rising edges of each cycle indicate that the solidification energy source is activated. Falling edges indicate that it is disabled. The time differential between each falling edge of the impulse waveform of the motor 1100 and the rising edge of the waveform of the solidification energy source activation signal 1102 is represented as A1. In preferred embodiments, A1 is maintained at a substantially constant pulse-by-pulse value of motor 118 to better ensure that the relationship between the rotational position of each facet 94a-f (FIG. 5B) and the activation of a synchronization pulse of the solidification energy of the solidification energy source 90 is substantially constant. However, in other examples, A1 is an initial test time that is only used as a starting point to dynamically calibrate the timing of the synchronization energy pulses sent by the source 90 with respect to a clock of the microcontroller CPU. In these examples, once the dynamically calibrated time is determined, it is used for subsequent synchronization energy pulses at which point the system no longer uses the timing of the motor drive pulses 118 to determine when to send the synchronization pulses of solidification energy.

In some cases, sensor 324 may be unnecessary because a specified delay time with respect to the activation pulses that drive motor 118 will reliably indicate when a line scan operation is about to begin (assuming the source of solidification energy 90 remain activated). However, in some examples, the pulses cannot be used to reliably indicate when a line scan operation is about to begin within the desired degree of accuracy. For example, facets 94 (a) to 94 (f) of the rotating energy deflector 92 may not be perfectly or consistently flat. In that case, the position of the scanning axis (y) of the solidification energy may not correlate well with the rotational position of the rotating energy deflector 92 or the impulse waveform 1100 (FIG. 24) of the rotating motor 118. In addition, the heat generated by the solidification energy source 90 can cause slight variations in the solidification energy path towards the solidifiable material and the angle of incidence at which the solidifiable material strikes. Therefore, the sensor 324 helps to better determine the time at which a line scan operation can begin (or is about to begin if the solidification power source 90 remains activated). This is particularly useful when object data is stored as time values because time values can be reliably correlated with specific positions along the direction of the scan axis with respect to the limit of the scan axis 344 of the envelope of construction 342 (FIG. 16 (b)). In some examples, a timer is reset when the sensor 324 generates a synchronization signal, and the object data is specified as time values in which the activation state of the solidification energy source 90 is changed with respect to to zero time value.

With reference again to FIG. 24, in some examples, the timer is reset (initialized) when the sensor 324 first indicates that it has received solidification energy. Waveform 1104 represents signals generated by sensor 324 and transmitted to the microcontroller. In some examples, the timer is initialized to zero at the rising edge of the sensor signal received by the microcontroller. For the first sensor signal pulse in FIG. 24, the rising edge is identified as 1104a. The filter 326 (FIG. 3) is intended to eliminate ambient light or other light sources other than solidification energy reflected by the rotating energy deflector 92. Otherwise, the microcontroller may prematurely initialize the CPU, causing the Microcontroller begin prematurely to apply solidification energy to solidify the solidifiable material. In some examples, the filter 326 is selected and / or adjusted to ensure that the sensor 324 generates an output signal for a period of time that is not longer than the time required for the reflected light of the rotating energy deflector 92 to pass through the detection length of the sensor 324 when the rotating energy deflector 92 is rotating at its operating rotation frequency. For example, if the detection length of the sensor 324 is 2 mm, the construction envelope distance in the direction of the scan axis (y) is nine (9) inches (228.6 mm) and the rotation frequency and the number of facets of the rotating energy deflector 92 produces a scanning speed of 2000 lines / second, the time required for the solidification energy to cross the sensor detection length will be 2 mm / ((2000 lines / second) ( 228.6 mm)) or 4.4 microseconds. Therefore, before performing an object creation process, the sensor 324 may be exposed to the solidification energy of the solidification energy source 90 and the rotating energy deflector 92. The output signals generated by the sensor 324 they can be observed in an oscilloscope to determine if the time required for solidification energy to pass through sensor 324 is 4.4 microseconds. If not, filter 326 can be adjusted or replaced until the correct detection time is observed.

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As previously indicated, solidifiable material is provided, such as a photo-curing resin under a substantially rigid or semi-rigid substrate 68 to receive the solidification energy transmitted through the substrate 68. The solidification substrate 68 is generally rigid or semi-rigid and substantially permeable to the energy supplied by the linear solidification device 88. In some examples, it is preferred that the energy of the linear solidification device 88 pass through the solidification substrate 68 without a significant decrease in transmitted energy or a significant spectrum alteration of energy transmitted to the solidification material in relation to the spectrum that affects the surface of the upper part of the solidification substrate 68. In the case where the energy of the solidification energy source 90 is light (including non-visible light such as UV light), the subtracted Solidification to 68 is preferably substantially translucent to the wavelength (s) of light supplied by the solidification energy source (90).

An example of a rigid or semi-rigid solidification substrate 68 is a translucent floating glass. Another example is a translucent plastic. A variety of different floating and plastic glasses can be used. Examples of plastics that can be used include transparent acrylic plastics supplied by Evonik under the name of Acrylite®. The term "translucent" is intended to indicate that the substrate 68 is capable of transmitting the wavelengths of light (including non-visible light such as UV light) necessary to solidify the solidifiable material and that the intensity of such wavelengths is not altered significantly when the light passes through the substrate 68. In the case of photopolymers, a photoinitiator is usually provided to initiate the polymerization / crosslinking process. The photoinitiators will have an absorption spectrum based on their concentration in the photopolymer. Said spectrum corresponds to the wavelengths that must pass through the solidification substrate 68 and that must be absorbed by the photoinitiator to initiate solidification. In an example where the solidification energy source 90 is a blue laser light diode, the Irgacure 819 and Irgacure 714 photoinitiators can preferably be used.

As solidification energy is supplied to it, the exposed surface of the solidifiable material will solidify according to a generally and preferably substantially linear pattern in the width direction (y-axis), creating a thin linear region of material that adheres to the substrate. of solidification 68. As indicated above, the downward movement of construction platform 43 (FIG. 1 and 2) can cause the object to break or distort if it remains adhered to solidification substrate 68. In some examples, The surface of the rigid or semi-rigid solidification substrate 68 that contacts the solidifiable material is coated with a material used to reduce the adhesion of the solidified material to the substrate 68. Suitable adhesion reducing agents include Teflon® coatings. Non-stick coatings such as nanorecovers can also be used.

To minimize the probability of distortion of the part due to the bonded solidified material, in some examples, the solidified material is periodically detached from the solidification substrate assembly 62. According to said examples, when the solidification energy source (which may be configured as any linear solidification device, such as an LED array 308 (FIG. 17) or linear solidification device 88 (FIG. 3-5C)) moves in the direction of the x-axis, is selectively activated to solidify a substantially linear section of the solidifiable material that extends along the direction of the scan axis (y). In addition, as the solidification energy source 90 moves in the direction of the x-axis, the solidification substrate assembly 62 is detached from a solidified section of solidifiable material. The solidified section detached from solidifiable material includes the substantially linear section of solidifiable material that is solidified by the solidification energy source. In some examples, the solidified material is released from the solidification substrate 68. In other cases, the solidified material is released from a film located between the solidification substrate 68 and the solidifiable material.

In some examples, this stripping operation comprises balancing the rigid or semi-rigid solidification substrate 68 with respect to the partially constructed three-dimensional object. In the embodiment of FIG. 3-4 solidification substrate 68 is curved along its length (that is, when viewed along the y-axis direction, solidification substrate 68 has a slight curvature in the x-axis direction). In some examples, the length of solidification substrate 68 is substantially parallel to the direction of travel of linear solidification device 88. An exemplary curved profile of solidification substrate 68 is shown in FIG. 6, which represents the solidification substrate assembly 62 in a rocked position. In the embodiment of FIG. 3-4, the solidification substrate 68 is arranged in an oscillating frame 66. The oscillating frame 66 includes a first and a second side of the oscillating frame 70a and 70b which are separated along the width (y axis) direction of the solidification substrate assembly 62. The first and second sides 70a and 70b of the oscillating frame each have stationary frame engagement surfaces 72a and 72b that are preferably also curved along their lengths (x-axis direction).

As shown in FIG. 3 and 4, the stationary frame 64 includes a first and a second oscillating frame coupling surfaces 74a and 74b that engage the coupling surfaces of the stationary frame 72a and 72b of the oscillating frame 66. In an exemplary embodiment, the radio of

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curvature of the solidification substrate 68 and the radius of curvature of each stationary frame coupling surface 72a and 72b are substantially equal. In another example, the upwardly oriented surfaces of the first and second sides 70a and 70b of the oscillating frame are curved and can have a radius of curvature substantially the same as that of the rigid or semi-rigid solidification substrate 68. The coupling of the coupling surfaces of the stationary frame 72a / 72b with the engagement surfaces of the oscillating frame 74a and 74b allows the oscillating frame 66 to balance with respect to the stationary frame 64 as the cam followers 106a and 106b cross the length of the first and second sides of swing frame 70a and 70b.

As mentioned above, cam follower assemblies 104a and 104b convert the movement of the timing belts 86a and 86b into the linear motion of the linear solidification device 88 in the direction of the length (x axis) of the assembly of solidification substrate 62. With reference to FIG. 3 and 4, cam follower assemblies 104a and 104b include cam followers 106a and 106b, each of which is represented as a pair of rollers. Cam followers 106a and 106b engage the upper surfaces of the sides of the oscillating frame 70a and 70b as the linear solidification device 88 moves in the direction of the x-axis. The coupling of cam followers 106a and 106b with the upper surfaces of the sides of the oscillating frame 70a and 70b applies a downward force to the sides 70a and 70b, causing them to swing. This, in turn, causes the solidification substrate 68 to balance, which detaches it from the solidified material adhered thereto, as best seen in FIG. 6 (which also represents the solidifiable material container 48 that is not shown in FIG. 3-4). It should be noted that in three-dimensional object manufacturing systems that use pattern generators that simultaneously project solidification energy in both construction envelope directions (x and y), it is generally not desirable to have any curvature in a solidification substrate, since such curvature It can result in image distortion. However, in some of the linear solidification processes described herein, said image distortion is minimized or eliminated because solidification energy strikes along a substantially flat linear path of small thickness. For example, while solidification substrate 68 is traversed in the direction of width (y axis) at a particular location along its length (x axis), it is substantially flat.

With reference to FIG. 7 to 13, an alternative embodiment of an apparatus for manufacturing a three-dimensional linear solidification device is shown. Similar numbers refer to similar parts in the previous embodiment. The apparatus includes a solidification substrate assembly 62 and a linear solidification device 88. The linear solidification device 88 is a linear scanning device that includes the same components and operates in the same manner as described above with respect to FIG. . 3-6. However, the solidification substrate assembly 62 is configured differently. In this embodiment, the solidification substrate 68 is provided as part of a mobile substrate assembly 212 that moves through the solidifiable material in the length direction (x-axis) of the solidification substrate assembly 62 as the linear solidification device 88 moves in the same direction. In contrast, solidification substrate 68 remains stationary in the embodiment of FIG. 3-6. In addition, the embodiment of FIG. 7-13 includes a film assembly 205. The film assembly 205 remains stationary as the solidification substrate 68 moves. The film assembly 205 includes a film 224 (not visible in FIGS. 7 and 8) that is place under solidification substrate 68 in the height direction (z axis). The solidifiable material is located under the film 224 and solidifies in contact with it, instead of solidifying directly in contact with the solidification substrate 68, as in FIG. 3-6.

As in the embodiment of FIG. 1-6, in the embodiment of FIG. 7-13 a flexible film mask can be provided with an array of transparent imaging elements (eg, LCD or transparent OLED) that can be made transparent or selectively opaque instead of a linear scanning device, thus allowing energy solidification is selectively provided to the solidifiable material in the direction of the shaft and while solidification energy is continuously supplied from the solidification energy source 90 to the rotating energy deflector 92. In one example, the flexible film is provided at the top of the rigid or semi-rigid solidification substrate 68 and moves with it as the substrate 68 moves along the length direction (x axis) of the solidification substrate assembly 62.

As best seen in FIG. 9A-C, the film assembly 205 comprises one or more frames, which in the embodiment of FIG. 9A-9C includes an inner frame 206 and an outer frame 220. As shown in FIG. 10 (in which the support 238b is removed), the film 224 has a central part (FIG. 9C) that is arranged inside the inner frame 206. The film 224 also has an inner peripheral part disposed between the lower edge 238 of the inner frame 206 and the bottom edge 236 of the outer frame 220. An outer peripheral part of the film 224 is sandwiched between an outwardly projecting lip 230 formed in the inner frame 206 and an upper surface 234 formed in the outer frame 220. The film 224 preferably stretches tightly and its central part is placed under the rigid or semi-rigid solidification substrate 68. When used during an object construction operation, the rigid or semi-rigid solidification substrate 68 applies a downward force

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on the film 224 as the substrate 68 moves in the direction of length (x axis), helping to planarize the exposed surface of the solidifiable material.

The film 224 is preferably a homopolymer or copolymer formed from ethylenically unsaturated halogenated monomers. Fluoropolymers are preferred. Examples of suitable materials for the protective film 224 include polyvinylidene fluoride (PVDF), ethylenecyclootrifl uoroethylene (ECTFE), ethylenetetrafluoroethylene (ETFE), polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA) and modified fluoroalkoxy and a tetrafluoromethyl tetrafluoroethylene known as MFA). Examples of suitable film materials 224 include PVDF films marketed under the name Kynar® by Arkema, ECTFE films marketed under the name Halar® by SolvaySolexis, ETFE films marketed under the name Tefzel by DuPont, PFA films marketed under the name Teflon® ®> -PFA by DuPont and MFA films marketed under the name Nowofol. MFA and Teflon® films are preferred.

As best seen in FIG. 7, the motor 76 is provided again and is operatively connected to the linear solidification device 88. However, the motor 76 is also operatively connected to the solidification substrate 68 so that when the motor 76 receives power, the shaft 78 rotates causing that the linear solidification device 88 and the solidification substrate 68 are moved in the direction of length (x axis).

FIG. 11 is a perspective view of the mobile substrate assembly 212. As shown in FIG. 7, 8 and 11, a pair of supports 238a and 238b connect the rigid or semi-rigid solidification substrate 68 to the distribution belts 86a and 86b. The supports 238a and 238b are separated from each other through the width (y-axis) or the direction of the scanning axis of the solidification substrate 68. Each support 238a and 238b includes a respective vertical panel, 250a and 250b, and a respective horizontal panel 214a and 214b (FIG. 11). The vertical panels 250a and 250b are each connected to a respective end of the rigid or semi-rigid solidification substrate 68 and to a respective horizontal panel 214a and 214b. The vertical panels 250a and 250b can be formed separately and then connected to their respective horizontal panels 214a and 214b or can be integrally formed therewith. The rigid or semi-rigid solidification substrate 68 is preferably constructed of glass or hard plastic. In one example, the substrate 68 is constructed of a rigid or semi-rigid transparent acrylic polymer. The rigid or semi-rigid solidification substrate 68 includes a first upper surface 268 that faces the linear solidification device 88 and a second lower surface 272 that faces the film 224 and the solidifiable material.

The timing belts 86a and 86b are used to move the rigid or semi-rigid solidification substrate 68 from a first position to a second position in the length direction (x-axis) with respect to the stationary frame 64, the film assembly 205 and the envelope of construction (total exposure area) of the solidifiable material under the film assembly 205. Timing belts 86a and 86b are connected to the respective pulleys 82a and 82b at one end and to the respective ends 80a and 80b of the drive shaft of motor 78 at another end (FIG. 7).

As best seen in FIG. 7 and 8, the supports of the mobile substrate assembly 238a and 238b are connected to their respective distribution tapes 86a and 86b on an upper surface of the horizontal panels 214a and 214b and to the respective linear bearings 110a and 110b (shown in FIG. 8) on a lower surface of horizontal panels 214a and 214b. Linear bearings 110a and 110b are slidably coupled with corresponding linear rails 112a and 112b to facilitate sliding movement of the rigid or semi-rigid solidification substrate 68 along the length (x-axis direction) of the solidification substrate assembly 62. Thus, when the engine 76 is running, each support 238a and 238b slides along its respective linear rail 112a and 112b causing the rigid or semi-rigid solidification substrate 68 to move along the length L (direction of the x axis) of the solidification substrate assembly 62.

As best seen in FIG. 9A-C, in one example, the outer frame 220 of the film assembly 205 is a generally rigid and rectangular structure shaped to cooperate with the inner frame 206. The inner frame 206 is a generally rigid and rectangular structure that includes an upper lip 230 (FIG. 10 and 13) projecting outwardly around the perimeter of the inner frame 206. The outer frame 220 fits under the upper lip 230. In some examples, the outer edge of the lip 230 and the outer perimeter of the outer frame 220 they are substantially aligned with each other and define a substantially continuous outer surface, as illustrated in FIG. 10.

With reference to FIG. 10, the outer frame 220 and the inner frame 206 are preferably fixed to minimize the likelihood of resin leaks through the space between the frames G2 and the area between the lip 230 of the inner frame 206 and the upper surface 234 of the outer frame 220. Numerous methods can be provided to minimize or eliminate such leakage. In one example, as shown in FIG. 10, the film 224 is stretched between the inner and outer frames 206 and 220, so that an inner peripheral part of the film 224 is located in the space G2, and so that an outer peripheral part of the film 224 is sandwiched between the inner edge 230 and the top most of the

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surface of the outer frame 220. In addition, the through holes 216 (FIG. 9A) formed on the upper surface of the upper lip 230 are aligned with the complementary holes 222 (FIG. 9A) formed on the upper surface of the outer frame 220, allowing elements fixing such as screws, bolts, etc. to secure the outer frame 220 to the inner frame 206. Therefore, in some examples, the fasteners are selected to minimize the amount of leakage in the area between the inner frame lip 230 and the upper surface of the outer frame 220 In other examples, some parts of the G2 space can be filled with a suitable resin blocking agent such as a cured resin. Suitable cured resins include silicones and epoxies.

Together, the film 224, the outer frame 220 and the inner frame 206 define a film assembly 205 that can be fixed to the stationary frame 64. In some embodiments, it is contemplated that the film assembly 205 will be replaced periodically due to the tension on the film 224. Thus, the film assembly 205 is preferably releasably fixed to the stationary frame 64 to facilitate replacement of the film assembly 205.

In certain embodiments, the film 224 is configured to provide a relief area that reduces or minimizes the probability of vacuum formation between the film 224 and the rigid or semi-rigid solidification substrate 68. In said embodiments, a portion of the film 224 includes a relief area (not shown) defined by small surfaces or grooves in its upper surface (which is in front of the rigid or semi-rigid solidification substrate 68). The embossed area is located under the rigid or semi-rigid solidification substrate 68 while also extending beyond the perimeter of the rigid or semi-rigid solidification substrate 68, preferably in the width direction (y axis). In some examples, the film assembly 205 has a width in the direction of the y-axis (FIG. 7) that is longer than the width (in the direction of the y-axis) of the rigid or semi-rigid solidification substrate 68. As shown in FIG. 10, the variation in width creates a space G1 between the edge of the rigid or semi-rigid solidification substrate 68 and the inner surface of the inner frame 206, creating a leakage path 232 from the atmosphere to the part of the relief area of the film 224 which is below and in front of the rigid or semi-rigid solidification substrate 68, thus minimizing the probability of vacuum formation between the film 224 and the rigid or semi-rigid solidification substrate 68. In the embodiment of FIG. 10, the space G1 creates a leakage path from the atmosphere to the area released from the film that is generally in the z direction (i.e. substantially parallel to the direction of movement of the construction platform 43 and the surface area of the film 224). However, other orientations of the leakage path are possible, such as one that is generally in the x-y plane. The film assembly 205 is attached to the lower side of the stationary frame 64 by means of fasteners connected to the frame 64 and to the lip protruding outward 230 from the inner frame 206 (see FIG. 10).

With reference to FIG. 7, 8, 12 and 13, the solidification substrate assembly 62 includes a detachment element assembly 208 (FIG. 8, 12) having at least one film shedding element, which in the embodiment shown are two film detachment elements 204a and 204b. The film detachment elements 204a and 204b are generally elongated rigid members that are separated from each other along the length direction (x axis) of the solidification substrate assembly 62 and on opposite sides of the rigid solidification substrate. or semi-rigid 68.

In a preferred embodiment, the film detachment elements 204a and 204b are operatively connected to the rigid or semi-rigid solidification substrate 68 to move in a coordinated manner with the rigid or semi-rigid solidification substrate 68. An example of an apparatus for facilitating this movement It is represented in FIG. 8 and 12. Each film detachment element 204a and 204b is connected to an opposite side of two supports 210a and 210b. The supports 210a and 210b are separated along the width direction (y axis) of the solidification substrate assembly 62 while the detachment elements 204a and 204b are separated along the length direction (x axis) of the solidification substrate assembly 62.

The support 210a has an upper surface with connectors 252a and 254a (FIG. 12) that are configured for connection to complementary connectors 240a and 248a (FIG. 11) formed in the horizontal panel 214a of the support of the solidification substrate assembly 238a. Correspondingly, the support 210b has an upper surface with connectors 252b and 254b (FIG. 12) that are configured for connection to complementary connectors 240b and 248b (FIG. 11) formed in the horizontal panel 214b of the solidification substrate assembly support 210b Connectors 252 a / b and 254 a / b can be male or female, threaded or without thread. Similarly, the complementary connectors 240a / 248a and 240b / 248b can be male or female, threaded or threadless. In FIG. 12, connectors 252 a / b and 254 a / b are male connectors suitable for insertion into corresponding female connectors (for example, threaded or threaded holes) 240 a / b and 248 a / b.

The connections between supports 210a / b and 238 a / b allow the film detachment elements 204a and 204b to move in coordination with the rigid or semi-rigid solidification substrate 68 as it advances in the direction along the length (axis x) of the solidification substrate assembly 62. The detachment elements 204a and 204b are preferably kept at a fixed distance from

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to the rigid or semi-rigid solidification substrate 68. As best seen in FIG. 13, the rigid or semi-rigid solidification substrate assembly 62 is preferably configured to maintain the upper surface 268 of the rigid or semi-rigid solidification substrate 68 below the inner frame 206 and the outer frame 220 of the film assembly 205. The lower surface 272 of the rigid or semi-rigid solidification substrate 68 is in abutment contact with the film 224, which facilitates the creation of a substantially flat surface of solidifiable material to which solidification energy is supplied. As shown in FIG. 13, an inner peripheral part of the film 224 is connected to the film assembly 205 at a height that is above the height of the lowest surface 272 of the rigid or semi-rigid solidification substrate 68. Therefore, the film part 224 that engages the lower surface 272 of the rigid or semi-rigid solidification substrate 68 remains below the film frame assembly 205 defined by the inner film frame 206 and the outer film frame 220. As best seen in the FIG. 13, the film assembly 205 is attached to the lower side of the stationary frame 64 through fasteners 280 (only one of which is visible in FIG. 13) connected to the stationary frame 64 and to the outward lip 230 of the inner frame 206.

With reference again to FIG. 13, the rigid or semi-rigid solidification substrate 68 also preferably has a beveled edge 266. The upper surface of the substrate 268 is positioned near the inner and outer film frames 206 and 220 and is disposed between the lower surface of the substrate 272 and the inner and outer film frames 206 and 220. As illustrated in the figure, in some examples, the upper surface of the substrate 268 has a surface area greater than the surface area of the lower surface of the substrate 272. The use of an edge beveled 266 and an upper surface 268 with a surface area greater than that of the lower surface 272 improves the ability of the substrate 68 to slide along the film 224 as the substrate 68 moves relative to the film 224 and the frames 206 and 220. As shown in FIG. 13, when viewed in cross section, the bottom surface 272 has a substantially flat region 264 disposed inwardly of the beveled edge 266.

In certain embodiments that include a beveled edge such as edge 266, measures are taken to reduce the likelihood of image distortion that can cause curved substrate geometries. In the embodiment of FIG. 13, the linear solidification device is preferably positioned within the beveled edge 266 to avoid such distortion. Therefore, in the example of FIG. 13, the solidification energy is received by a substantially flat surface 270 and is transmitted from a substantially flat bottom surface 272. In some preferred examples, solidification energy is not transmitted from the beveled edge 266 to the solidifiable material under the film 224.

In FIG. 1 -4, the three-dimensional object is progressively constructed in a vertically upward direction (z axis) by moving the construction platform 43 progressively downward within the resin container 48 (FIG. 2). However, other orientations and construction directions can be used. FIG. 19-20 represent another system 350 for making a three-dimensional object 316 from a solidifiable material 302. FIG. 2 represents the system 350 with the construction platform 354 in a position relative to the rigid or semi-rigid solidification substrate 68. In FIG. 19, the newly solidified material adheres to the rigid or semi-rigid solidification substrate 68. The solidifiable material 352 is of the type previously described for the embodiment of FIG. 1-4. In system 350, construction platform 354 is suspended on a support 356 that is attached to an elevator 358. Elevator 358 progressively moves construction platform 354 in a direction vertically upwards during a construction operation of objects.

The linear solidification device 88 is placed under the rigid or semi-rigid solidification substrate 68 and moves in the direction of the length (x-axis) to solidify the solidifiable material 352. As best seen in FIG. 20A, the linear solidification device 88 is constructed in substantially the same manner as in the previous embodiments. However, it is oriented in a vertically opposite direction (z-axis) with respect to the previous embodiments and can also be configured as an LED matrix or a laser diode with a laser scanning micro mirror. Therefore, the lens 98 is positioned vertically (z axis) above the rotating energy deflector 92 and vertically (z axis) below the light aperture 100 (FIG. 5a and 5b). In FIG. 20A, the solidification energy source 90, which is preferably a laser diode, is not visible. However, it is positioned to direct the solidification energy in the yz plane towards the energy deflector 92 as the energy deflector 92 rotates. Therefore, as the linear solidification device 88 moves in the x direction , the solidification energy is progressively scanned in the direction of the axis and to selectively solidify certain locations along a generally-and preferably-substantially linear scanning path (as dictated by the shape of the three-dimensional object at a given position on the axis x). If a given location of the axis and in the solidifiable material will receive solidification energy depends on whether the solidification energy source 90 is supplying solidification energy when the facet 94a-94f which is in optical communication with the solidification energy light source it reaches the rotational position corresponding to that location of the y axis.

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The apparatus for moving the linear solidification device 88 is similar to that described in the previous embodiments. In one example, a pair of linear sliders is suspended from the lower face of the upper horizontal surface of the housing 360. The connectors on each side of the light opening 100 in the linear solidification device 88 connect the linear solidification device 88 to the linear bearings that slide on the rails. An engine such as the engine 76 is provided with an axle, timing belt and pulley assembly to slide the linear solidification device 88 in the direction of length (x axis).

Unlike the embodiment of FIG. 1-4, there is no solidifiable material container in which construction platform 356 is submerged during an object construction process. Instead, the solidifiable material is periodically dispensed in a construction tray that is defined by the film assembly 205 described above. In FIG. 20A, the film 224 (not shown) is located above the rigid or semi-rigid solidification substrate 68 and below the construction platform 356. The film 224, the inner frame 206 and the outer frame 220 collectively define a shallow container It contains solidifiable material. The rigid or semi-rigid solidification substrate 68 supports and is placed under the film 224 so that a peripheral part of a rigid or semi-rigid solidification substrate rests on the housing 360 (FIG. 19). An opening 362 on the upper surface of the housing 360 provides an optical path between the linear solidification device 88 and the solidifiable material 352. As an object is constructed, the solidifiable material 352 solidifies and adheres to the object 366 (FIG 19), thereby reducing the amount of solidifiable material 352 in the reservoir. Level detector 361 projects the light and detects the returned light to determine the level of liquid in the container. When the level falls below a selected threshold, additional solidifiable material is dispensed into the reservoir (using an apparatus not shown).

With reference to FIG. 20B-20D, a part of an alternative version of the system 350 is represented to make a three-dimensional object. FIG. 20B and 20C represent a worktable assembly 369 that can be used in the system 350 of FIG. 20 A. System 350 also includes a linear solidification device 88 that can be configured as described above. A cover 400 can also be provided to contain the optical and solidification energy sources in the linear solidification device 88.

According to the example shown, the system 350 comprises a linear solidification energy device 88 that travels in a first direction (x axis) as solidification energy is transmitted in a second direction (y axis). In addition, a solidification substrate 388 moves in the first direction (x axis) as the linear solidification device 88 moves in the first direction (x axis). The three-dimensional object is built progressively upside down in the vertical direction (z axis) during the object creation process.

The worktable assembly 369 of FIG. 20B comprises worktable 370 and a solidification substrate assembly 371 comprising film assembly 205, and solidification substrate 388. System 350 also includes a carriage 372 and stripping members 374a and 374b. The carriage 372 is used to support and move the linear solidification device 88 in the direction of the x-axis. The detachment elements 374a and 374b are used to separate the film 224 from the film assembly 205 of the solidified three-dimensional object. The film assembly 205 acts as a container or reservoir to contain solidifiable material. Level sensor 361 is provided to detect the level of solidifiable material contained in the film assembly 205, so that solidifiable material can be added as necessary to maintain the desired level.

The worktable 370 includes an opening 376 in which the film assembly 205 is disposed. The film assembly 205 may also include handles 378a and 378b which are separated from each other in the direction of the x-axis to facilitate removal and / or the replacement of the film assembly 205 of the worktable assembly. The cam latches 386a and 386b are separated from each other in the direction of the shaft and to removably lock the film assembly 205 in place in the opening of the worktable 376.

Solidification substrate 388 of FIG. 20B-20D is rigid or semi-rigid and is preferably formed as a partial cylinder (half cylinder of the circumference of a complete cylinder or less) having its longitudinal axis oriented in the direction of the solidification energy scanning axis (y axis). In some preferred examples, the solidification energy crosses the length of the solidification substrate 388 at a substantially fixed circumferential location along the substrate 388. A close-up cross-sectional view of a portion of the film assembly 205, the linear solidification device 88 and substrate 388 is shown in FIG. 20D. As shown in the figure, the solidification substrate 388 is arranged in an opening inside the carriage 372 so that the substrate 388 is concave with respect to the linear solidification device 88. The substrate 388 has an internal surface defining a radius internal and an external surface that defines the outer radius, where the outer radius is larger than the internal radius. The linear solidification device 88 is positioned such that the inner surface of the substrate 388 is between the linear solidification device 88 and the outer surface of the substrate 388.

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The solidification substrate 388 is positioned so that at least a portion thereof moves away in the vertical direction (z axis) from an upper surface of the carriage 372. The solidification substrate 388 has a vertex 389 which is the circumferential location of the substrate 388 which is separated from carriage 372 by the furthest distance (compared to the other circumferential locations). In some preferred examples, the linear solidification device 88 is positioned so that the solidification energy is selectively projected along the length of the substrate 388 substantially at vertex 389. In some examples, the housing opening 100 (FIG. 5B) is oriented parallel to the length of solidification substrate 388 and at a position of the x-axis that is substantially the same as the position of the x-axis of apex 389.

Solidification substrate 388 is preferably formed from a translucent and / or transparent glass or plastic. In some preferred examples, substrate 388 has a radius of curvature that ranges from about 0.2 inches (5.1 mm) to about 0.8 inches (20.3 mm), preferably from about 0.4 inches (10.2 mm) to about 0.6 inches (15.2 mm), and even more preferably about 0.5 inches (12.7 mm). In the same or other preferred examples, solidification substrate 388 has a thickness ranging from about 0.5 mm to about 3.5 mm, preferably from about 0.6 mm to 3.0 mm, and more preferably from about 1.5 mm to about 2.5 mm. In one example, the thickness is approximately 2.0 mm.

With reference again to FIG. 20D, the film assembly 205 (which is configured as described above) sits on top of the carriage 372 and the solidification substrate 388 in the vertical direction (z axis). The use of a curved solidification substrate 388 reduces the surface contact area between the substrate 388 and the film 224, thus reducing friction between the substrate 388 and the film 224 while the substrate 388 moves in the direction of the x-axis with respect to to the movie 224.

In some examples, during an object construction operation, the construction platform 356 (FIG. 20A) or the most recent solidification surface facing down of the object is immersed in a volume of solidifiable material contained in the film assembly 205 ( which acts as a deposit of solidifiable material) until a desired separation between the most recently solidified downward oriented surface of the object and a solidification substrate is obtained. During immersion, the pressure forces build up and force or expel a certain amount of solidifiable material laterally away from the object. In the case of a flat solidification substrate, the pressure forces may be undesirably high and could distort the three-dimensional object. Curved solidification substrate 388 reduces said pressure forces.

The linear solidification device 88 functions similarly to the previous embodiments. A motor 382a and an optional motor 382b are operatively connected to the linear solidification device 88 to move the device 88 in the direction of the x-axis. In some examples, motors 382a and 382b are stepper motors that are driven in "phase" units of the motor that can be correlated with a linear distance in the direction of the x-axis and used to define data from the object strip, such as outlined below.

Carriage 372 is operatively connected to two externally threaded shafts 380a and 380b that are separated from each other in the scanning direction (y axis). The axes 380a and 380b are supported and connected to the worktable 370 by the supports 396a and 397a (axis 380a) and the supports 396b and 397b (axis 380b). The carriage 372 is connected to the threaded shafts 380a and 380b by the corresponding internally threaded nuts 384a and 384b. The activation of the motor 382a (and optionally, the motor 382b) causes the axes to rotate around their longitudinal axes (which are oriented in the direction of the x-axis). As the axes 380a and 380b rotate, the coupling of the external threads of the shaft with the threads of the internal nut causes the carriage 372 to move in the direction of the x-axis. The system 350 may also include a limit switch sensor such as the limit switch sensor 346 shown in FIG. 16 (b) to allow the x-axis position of the linear solidification device 88 to be initialized reliably.

Carriage 372 is supported in the vertical direction (z axis) by internally threaded nuts 384a, 384b and axes 380a and 380b. Linear bearings 402a and 402b are coupled to the carriage surface 372 oriented vertically upwards (z axis) and slidably coupled to rails 404a and 404b formed on the lower side (surface oriented downward in the direction of the z axis) of the work table 370.

As previously indicated, engine 382b is optional. In certain cases, only a single 382a engine is required. Pulleys 390a and 390b are provided at the distal ends of the externally threaded shafts 380a and 380b. A synchronization belt 394 is applied to pulleys 390a and 390b so that when the externally threaded shaft 380a rotates around its longitudinal axis, the pulley 390a rotates around its central axis, causing the synchronization belt 394 to begin to circulate. The circulation of the synchronization belt 394 in turn causes the pulley 390b to rotate around its central axis, which in turn causes the externally threaded shaft 380b to rotate around its longitudinal axis. The rotation of the externally threaded shaft 380b causes the corresponding side of the carriage 372 to move in the direction of the x-axis due to the coupling of the externally threaded shaft 380b and the internally threaded nut 384b.

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The tensioner 393 can also be provided to maintain a desired tension of the synchronization belt 394. In those cases where the optional motor 324b is provided, the synchronization belt 394 can be removed.

As best seen in FIG. 20D, the position of the solidification substrate 388 drives a portion of the film 224 of the film assembly 205 in a vertical direction (on the z axis) upwardly away from the upper surface of the carriage 372 and the linear solidification device 88. detachment elements 374a and 374b are operatively connected to the carriage 372 and separated from each other along the direction of the x-axis on the respective sides of the solidification substrate 388. The film 224 is positioned between the detachment elements 374a, 374b and the upper surface of the carriage 372. As the solidifiable material solidifies at the location of the apex of the substrate 389, it will tend to solidify in contact with the film 224 and will adhere to it. As the carriage 372 moves in the direction of the x-axis, the film detachment elements 374a and 374b move in the same direction and pull the film 224 vertically downward (z-axis) away from the solidified object. The supports 399a (not shown) and 399b are connected to the detachment elements 374a and 374b and are positioned within the film assembly 205. The supports 399a and 399b are also connected to the carriage 372 to move with the carriage 372 when the carriage 372 moves in the direction of the x-axis. Thus, the system 350 selectively solidifies the material in the scanning direction (y axis) while moving a linear solidification device 88 and the film peeling elements 374a and 374b in the x-axis direction.

Instead of using the film assembly 205, the system 350 to make a three-dimensional object of FIG. 19 and 20A-D can use a container formed from polymeric materials. In one example, a reservoir comprising a transparent elastic bottom and elastic side walls is used. In certain implementations, both the transparent flexible bottom and the non-elastic side walls are formed from the same or different silicone polymers. In another implementation, a cuvette comprising non-resilient acrylic side walls and an elastic silicone bottom is used. In another example, the bottom of the container is defined by a rigid or semi-rigid transparent solidification substrate 68 that is connected to side walls formed by an elastic or plastically deformable polymeric material. In a further example, the substrate 68 may be coated with an elastic transparent material, such as a silicone, which extends only a part of the path towards the side walls, leaving a peripheral space around the coating and between the coating and the side walls. In yet another example, the substrate 68 may be coated with an elastic transparent material that extends to the side walls. In some examples, an inclination mechanism can be provided that tilts the cuvette with respect to the construction platform 356 to detach the solidified solidifiable material from the bottom of the cuvette. A non-elastic material such as a transparent non-elastic film can also be provided as a layer on the upper part of the elastic bottom between the elastic bottom and the construction platform 356.

As in the previous embodiments, during an object construction process, solidifiable material 352 solidifies in contact with film 224, causing film 224 to stretch when object 366 is stretched upwards (axis direction z) and away from the housing 360. In this way, the movement of the construction platform 354 is preferably controlled to avoid damaging the film 224 and / or the object 366.

In the embodiments of FIG. 19 and 20A-D, a flexible film mask can be provided with an array of variablely transparent imaging elements (eg, LCD or transparent OLED) that can be made transparent or selectively opaque, thus allowing solidification energy is provided selectively in the direction of the axis and while continuously supplying solidification energy from the solidification energy source 90 to the rotating energy deflector 92. In one example, the flexible film mask is provided on top of the solidification substrate. rigid or semi-rigid 68. The solidification energy device 88 may be realized as shown in FIG. 5A-C. In addition, the rotating energy deflector 92 can be replaced by a laser scanning micro mirror.

In accordance with certain implementations of the processes and apparatus for manufacturing three-dimensional objects described herein, a method for representing object data for use in controlling the action of the linear solidification device 88 is illustrated in FIG. 14-16 (g). Typical types of files used to generate object data include STL files (stereo lithography) or other CAD files (computer-aided design) are usually transferred to rapid prototyping systems in formats such as SLC, CLI sector data files or Voxelized data files that can include data formats such as BMP, PNG, etc. However, any type of data input can be used and converted internally to create the image data used by the linear solidification device 88. The object data corresponds to the energy pattern supplied by the linear solidification device 88 and can be generated by a control unit or by an external source or device (for example, a network or storage device).

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As an exemplary three-dimensional object, a single cylinder 300 is shown in FIG. 14. Locations on or inside the cylinder can be characterized by x, y, and z axes as shown. In certain implementations of linear solidification devices, the intensity and duration of the solidification energy supplied at a location x, and particular cannot be varied. As a result, those locations in the x-plane, and that receive solidification energy will solidify at substantially the same depth. In such implementations, it may be useful to perform a "cut" data operation in which a computer representation of the three-dimensional object is cut to create a plurality of sections in the direction of the construction axis (z axis), each of the which represents a uniform depth across all points across the xy plane. Each of said sections may correspond mathematically or be represented by a set of object layer data. An exemplary illustration of said sheets is plotted in FIG. 15. As shown in FIG. 15, a data representation of the object 300 may be further represented as a plurality of construction axis cuts (z axis) 302i, wherein the total number of cuts n is substantially equal to the height of the object as it is constructed divided by the solidification depth provided by the linear solidification device 88. The sheets 302; they can be represented mathematically as sets of object layer data in which each layer is defined by x coordinates, and that represent its contours and a z-axis value that represents its location along the construction axis, with Az values between segments adjacent representing the thickness of the layer.

Each set of object layer data can be plotted as a plurality of strips that have a length along the direction of the scan axis (y axis) and a width along the direction of the x axis, with the strips arranged across the direction of the x axis. With reference to FIG. 16 (a), a view taken along the vertical direction (z axis) of a graphic representation of a segment of individual object data 302 is provided. The individual part 302 can be represented as a plurality of adjacent strips 304j, Which is represented as m strips. The dotted line is not part of the data representation, but is provided to show the generally circular shape defined by strips 304j. In the example of FIG. 16, the strips have a width corresponding to the direction of movement of the linear solidification device 88 (x axis) and the length corresponding to a direction other than the direction of movement of the linear solidification device 88 (y axis). In the specific example of FIG. 16 (a), the direction of the chain length is substantially perpendicular to the direction of the x-axis.

Each strip 304j graphically represents a representation of data (preferably provided in a form readable by a computer processor) of those locations of solidifiable material that will solidify in the y-axis direction for a given x-axis location. The locations can also be defined in relation to the limits of the envelope of the construction, such as the limit of the scan axis 344 and the limits of the x-axis 343 and 345 of FIG. 16 (b). The control unit (not shown) receives data indicating the location of the solidification energy in the direction of the x-axis, for example, as indicated by the position of the linear solidification device 88 in the direction of the x-axis. The control unit also receives data representation (strips 304j) and directly or indirectly associates each chain 304j with an x-axis position in the construction envelope 342 defined within the exposed surface of the solidifiable material. Therefore, a position within a chain in the data representation corresponds to a position on the exposed surface of the solidifiable material.

In FIG. 16 (a) x0 corresponds to the position of the linear solidification device 88 at which solidification will begin. The increase x1-xo represents the solidification width in the direction of the x axis provided by the linear solidification device 88. Thus, when the linear solidification device is in the x0 position, the solidification energy source 90 will supply solidification energy when a facet 94a-f with which it is in optical communication has a rotational position corresponding to the locations of the axis and in the construction envelope 342, in which the strip defined between x0 and x1 is present. In the illustrated embodiments of FIG. 5A-C, the length of a facet 94 (a) - (f) of the rotating energy deflector 92 corresponds to the maximum scannable dimension of the shaft and of the construction envelope 342, that is, the maximum solidification length in the direction of the y axis. However, any single chain 304j can correspond to a solidification length of the shaft and less than the maximum dimension of the axis construction envelope and explorable.

Since the linear solidification device 88 moves along the length direction (x axis) of the solidification substrate assembly 62, it will solidify regions of solidifiable material corresponding to each strip 304j. Each location of the x axis corresponds to a particular strip 304j. In certain embodiments, a linear encoder is operatively connected to the motor 76 and / or motor shaft 78 to determine the position of the x-axis of the linear solidification device 88.

The data of the object layer illustrated graphically in FIG. 16 (a) can be mapped onto a building envelope 342 as shown in FIG. 16 (c). Each strip 304j can be defined by an x coordinate (or x coordinate pairs) and one or more coordinates that define the solidification regions at the particular location of the x axis.

In some examples, each string 304j may be represented by a corresponding set of string data. In a preferred embodiment, the string data set comprises a set of time values. In another preferred embodiment, the string data set comprises a string number n and a set of time values. In certain cases, the chain number n 5 corresponds to a linear scan number. For example, using the formula (1) described above, a maximum number of linear scans (Nmax) for a construction envelope length L can be calculated and each linear scan will have an associated corresponding chain index number. For any particular object layer, the regions of the building envelope 342 along the x-axis direction may not solidify and may not scan. However, all regions in which a single linear scan can occur in the x-axis direction can be assigned a string number. Thus, for a given speed of the motor 76, a given number of facets F of a rotating energy deflector 92 and a determined rotational speed of the rotating energy deflector 92, there will be a maximum number of linear Nmax scans within the construction envelope 342 and a corresponding number of sets of data strings, each of which may or may not have actual scan data (object data), depending on whether a scan will be performed at its corresponding x-axis location. In the example of FIG. 16 (c), thirteen linear scans are used to form the object layer represented by strips 304j and each linear scan corresponds to a linear scan index ranging from na n + 12 and a unique set of string data that have a string index that goes from na n + 12.

20 The usual control systems, including microcontrollers, will have a built-in delay time between when solidification data is read and when solidification power source 90 is switched to an activated or deactivated condition. The delay time may be variable and may cause errors in the dimensions of the three-dimensional object being constructed. In one example, a microcontroller is provided with the systems for making a three-dimensional object described herein that has a delay time of no more than about 80 nanoseconds, preferably no more than about 60 nanoseconds, and even more preferably no more. of approximately 50 nanoseconds. The part error can be related to the alternation delay time as follows:

(3a) Error = (LBE) (RPM) (F) (ttoggie iag) / (60sec./min.)(0.001 mm / micra)

30 where, Error is the maximum variation in the dimensions of the piece (microns) due to the time of

alternation delay;

LBE is the distance of the construction envelope in the direction of the scan axis (y) (mm);

RPM is the rotation frequency of the rotating energy deflector 92 (revolutions / minute);

F is the number of facets in the rotating energy deflector 92; Y

35 ttoggie lag is the time required for the microprocessor to alter the state of the source of

solidification energy.

In some preferred implementations, the Error is preferably no more than 90 microns, more preferably no more than about 90 microns, still more preferably no more than about 70 microns, and even more preferably no more than about 50 microns.

40 FIG. 16 (d) provides a table illustrating exemplary sets of string data that correspond to the object bands shown in FIG. 16 (c). Chain indices begin with n = 0 on the left edge (xü) of construction envelope 342 and end at a maximum chain number Nmax on the right edge of construction envelope 342. Therefore, some data sets string will not have any object data associated with them, since they do not correspond to the locations of the x-axis where solidification occurs. In FIG. 16 (d) no solidification occurs before the chain index n = 20 and no solidification occurs after the chain index n + 12. Therefore, there are no entries in the table of FIG. 16 (d) for the x-axis locations where solidification does not occur within construction envelope 342.

Each string data set represented in FIG. 16 (d) has a start code that is represented 50 in hexadecimal notation by a series of eight Fs. Going from left to right, the string index n for the string data set is as follows. Following the string index, a series of time values is provided. Each time value represents an activation status event of the solidification source. In one example, the activation states are enabled or disabled. Time values can take a variety of forms. However, in an implementation they are defined as the 55 elapsed times of a CPU clock in the microcontroller unit used to operate the system to make a three-dimensional object. In one example, the CPU has a clock speed of 66MHz and the time units are CPU marks. In an example where the line scan speed is 1000 lines per second, the maximum scan length of each line on the scan axis (y-axis direction) corresponds to 66,000 marks. Therefore, the set of string data at n = 20 indicates that the

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Solidification power source 90 will be activated at 22,000 marks and deactivated at 44,000 marks. The string data set at n = 21 indicates that solidification energy source 90 will be activated at 20,000 marks and deactivated at 46,000 marks. In a preferred embodiment, a timer is provided (such as a software timer programmed in the microcontroller unit) that is reset at the beginning of each linear scan, and the beginning of each linear scan is synchronized with the axis limit of envelope construction scan 344 using a sensor 324 of FIG. 5C in the manner described above. Therefore, the marks are defined in relation to a zero start time when the timer is reset, at which point the line scan operation is at the limit of the scan axis 344 (FIG. 16 (b)).

In some examples, a host transmits string data sets to a microcontroller unit that operates the system to produce a three-dimensional object for each possible linear scan (that is, for each string ranging from 0 to Nmax-1) although some of the string data sets may not have object data (for example, no CPU brand value) associated with them because solidification does not occur at the location of the x-axis to which they correspond. While this technique can be used, it consumes an excess of processor capacity of the microcontroller unit involved in reading string data for string data sets corresponding to the locations of the x-axis where solidification does not occur. Therefore, in some examples, only the string data sets that contain object solidification data (for example, CPU mark values) are transmitted to the microcontroller unit. In such cases, it is convenient to define a computer memory index m having values ranging from 0 to one less than the maximum number of transmitted sets of Mmax data strings, where m identifies only each set of string data transmitted to the microcontroller unit In the example of FIG. 16 (d), there is a total of Nmax sets of string data defined for the entire building envelope 342 by the host computer. However, only 13 sets of string data include object solidification data. Therefore, assuming that the linear solidification device 88 moves from left to right in FIG. 16 (c), the first set of string data transmitted by the host computer to the microcontroller unit will have a computer memory index of m = 0 and a string index of 20. The value of the string index will correspond to a specific location along the x axis within the construction envelope 342. However, the memory index of the computer m will not necessarily correspond. Therefore, the microcontroller unit only needs to read 13 sets of data series instead of Nmax-1 sets of data strings.

In some cases, linear solidification devices 88 using a rotating energy deflector 92 may be subject to variability in the linear scanning speed in the scanning direction (y axis). Each facet 94a-f will have a rotation position corresponding to a location along the scan axis (ie, a "center point") in which the solidification energy will deviate perpendicularly to the solidifiable material and the opening 100 in the housing. of the linear solidification device 88. At the central point, the distance traveled by the solidification energy from the rotating energy deflector 92 to the solidifiable material will be at a minimum with respect to the locations away from the central point. In rotational positions located far from the center point in the scanning direction (y axis), the scanning speed in the direction of the axis and will be faster than the proximity of the center point. In addition, the speed will increase as the distance from the center point increases. At a constant rotation frequency for the rotating energy deflector 92, the speed increase is directly proportional to the distance from the center point. This variable scan speed depending on the position of the scan axis (y axis) can cause inaccuracies in the three-dimensional object.

In some examples, the string data used to determine when to toggle the activation state between ON and OFF of the solidification energy source 90 is adjusted to take into account the speed variations of the scan axis. In one embodiment, the string data values representing changes in the activation state (for example, the number of CPU marks as exemplified in FIG. 16 (d), (f) and (g) ) are adjusted based on their distance corresponding to the center point). In one implementation, the string data at any string index value n is adjusted as follows:

3 (b) New CPU marks = Old CPU marks + ACPU marks * C

where, ACPU marks are calculated by subtracting the old CPU marks from the CPU marks from the center point, and C is a dimensionless constant. The variable "CPU marks of the central point" refers to the number of CPU marks in which the solidification energy will hit the central point. In general, it will correspond to the midpoint of a complete scan line along the direction of the scan axis.

Equation 3 (b) can also be modified for use with linear distances before they become CPU marks. For example, referring to FIG. 15, a three-dimensional object can be laminated in a plurality of cuts such as 302i where i varies from 1 to the maximum number of sheets n. A given segment can be projected onto the construction area as shown in FIG. 16 (c). Each scan line 304j will have locations that define a distance from a

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reference location along the direction of the scan axis (for example, the edge 344 where y = i) where the activation state of the solidification energy source 90 changes. The center point can also be defined in relation to the same reference location. For each location along the x-axis, there will be a plurality of y-axis values (in relation to the y0 344 edge) at which the activation state changes. For each chain shown in FIG. 16 (c), the activation status will change twice. Thus, for a given position along the x axis, each value of the scan axis (y) to which the solidification energy energization state changes can be corrected to take into account the variation of the scan axis (y) in the solidification energy scan speed as follows:

3 (c) ynew = yold + (y center point - yold) * C

where yold is a position of the axis and with respect to the reference location of the axis and (for example, the edge 344 in FIG. 16 (c)) in which the activation state changes as determined by placing (mathematically or graphically) a sheet 302i of the three-dimensional object in a construction envelope;

and central point is the location of the central point with respect to the reference location of the axis and (for example, the edge 344 in FIG. 16 (c));

and new is the new corrected value of the axis and in which the activation state changes; and C is a constant without dimensions.

Ynew values can be converted to CPU marks to define the string data for solidification.

The value of the dimensionless constant C can be determined by trial and error. In one example, a plurality of linear sections solidify along a direction that is substantially perpendicular to the direction of the scan axis (y), for example, along the direction of the x axis. The string data on which the linear sections are based are such that each line is equally separated from its neighbors. In the case of a data string that says String (n) = (FFFFFF, n, 10000, 10500, 11500, 12000, 22000, 22500, 32500, 33000, 43000, 43500), each linear section would be expected to have a thickness of the scan axis corresponding to 1000 marks of the CPU and equal separations between linear sections equivalent to 10,000 marks of the CPU. If the scan speed varies along the direction of the scan axis (y), the actual solidified linear sections will not be separated by equal amounts. For example, when the scan speed is faster at the ends of the scan line relative to the center point, the separations between adjacent linear sections will increase as it moves along the axis and from the center point (already be positive or negative direction of the y) axis. C can be calculated by relating the distances between two adjacent chains (and / or averaging the relations of adjacent neighbors) or by making adjustments to C and repeating the solidification process until the separations between linear sections are substantially equal.

Therefore, in a method for manufacturing a three-dimensional object, a three-dimensional object is cut into adjacent sheets along a construction axis (for example, as shown in FIG. 15). Each sheet is then subdivided into a set of linear bands, each of which extends along the scanning direction (for example, the y-axis). A central point is determined by determining the position along the direction of the scan axis at which the distance between the solidification energy deflected by the rotating energy deflector 92 and the solidifiable material is minimal. In a variation, each string becomes a set of scan axis values (which can be, for example, linear distances with respect to a construction envelope limit or CPU mark values) at which the state of change solidification power source activation 90. Each value of the scan axis is corrected to take into account the variation in the scan speed along the scan axis, preferably in an amount that varies with the distance between the location of the value of the scan axis along the scan axis and the center point, such as using equation 3 (b). The corrected scan axis values are subsequently used by the microcontroller to perform the solidification process. In another variation, the set of linear strips is converted to CPU marks and then corrected, for example using equation 3 (b).

In many three-dimensional object creation processes, there will be several adjacent layers that are identical and, therefore, can be represented by identical object layer data. With reference to FIG. 16 (e), the data of the object layer is represented graphically that can be used to form several layers. In some cases, it is preferable to perform line scan operations when the linear solidification device 88 moves from left to right and from right to left along the x axis. This presents no problem when the object is symmetrical with respect to the midline of the x-axis direction. However, when multiple identical asymmetric layers are formed, the microcontroller unit must read the string data sets in the opposite order when the linear solidification device 88 moves in opposite directions. For example, the table in FIG. 16 (f) represents multiple sets of string data that correspond to the object layer data of FIG. 16 (e). When the linear solidification device 88 moves from left to right, the first

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String data set in which solidification occurs has a string index of n = 20 and a computer memory index value m of zero. The last set of string data in which solidification occurs has a string index of n = 60. When the linear solidification device 88 reverses the direction to go from right to left, it cannot perform solidification starting with the computer memory index m = 0 and the data chain index n = 20 because that data was defined for the left side of FIG. 16 (e), not the right side. Therefore, performing line scan operations based on such data would solidify a pattern that is the inverse of the desired pattern. The microcontroller unit or host can calculate and store complete sets of data strings for the right-to-left address based on the data generated for left-to-right operation. However, this operation would consume excessive memory and processor capacity.

In one method of operation, the host reverses the data for adjacent identical layers and transmits them to the microcontroller unit. According to the method, layer data of identical three-dimensional objects corresponding to the adjacent first (even) and second (odd) layers of solidifiable material used to form the three-dimensional object are provided. The object layer data is subdivided into respective first and second pluralities of object cross-section strips, where each object cross-section chain in the first plurality of object cross-section strips has a set of strip data and a n value of strip index (pair) ranging from 0 to the maximum index value of Nmax-1 in the first plurality of object cross-section strips. Each strip in the second plurality of object cross-section strips has a set of strip data and a corresponding chain index value n (odd), and the string data corresponding to each respective value of n (odd) for the second plurality of cross objects - the section strips equal the string data for the first plurality of object cross section strips corresponding to the chain index value n (even) equal to Nmax-1 minus the respective value of n (odd). As each odd layer solidifies, the host computer can simply identify the even layer data chain that corresponds to each odd layer data chain and transmit the even layer data chain to the microcontroller, avoiding the need to store a odd layer string data set. The use of this inversion technique allows multilayer data that solidifies in opposite directions to be determined by creating object layer data for a single layer and either inverting (for solidified layers in the opposite direction of the x-axis) or using it. (for solidified layers in the same direction of the x-axis) for all subsequent layers that have the same cross-sectional shape.

An exemplary inversion used to reduce the storage capacity of a computer-readable medium required to store three-dimensional object data corresponding to a plurality of object layers can be described as follows: a first set of object layer data is stored in a computer readable medium. The first set of object layer data comprises a first set of data strings such as those represented in FIG. 16 (d), (f) and (g). Each data string in the first set can be represented as d (0, m), where 0 indicates that the string belongs to the first set, and m is a unique computer memory index value of the string. The index values m range from 0 for the first data string to Mmax (or Mtotal). The highest index value will be Mmax-1 (because the first value is zero).

A program is stored in the computer-readable medium (which may be the same or different from the first object layer data set) with instructions to calculate a second set of data strings for a second set of data Object layer The layers to which the first and second sets of object data correspond are preferably adjacent to each other and define a sequence of alternate layers (first set, second set, first set, second set, etc.). The string data for the second set of object layer data can be calculated using the following equation or using any set of equations so that the string data for the second set of object layer data corresponds to that of the first layer of object data according to the following equation:

(4) d (1, m) = d (0, Mmax-1-m)

where, d (1, m) is the string data for layer 1 at a given value of the memory index

of computer, m.

Using equation (4), the host can simply identify the data chain for the 0 th layer that corresponds to each data chain for the 1st layer and transmit it to the microcontroller. Neither the host nor the microcontroller needs to store the d (1, m) strings in memory. As mentioned above, each location along the x-axis direction of construction envelope 342 may correspond only (directly or indirectly) to a chain index n. The memory index of the computer is used to avoid storing data strings that are empty because they correspond to locations where solidification will not take place. However, the data strings for the entire building envelope can be related to each other using a

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equation similar to equation 3a replacing m with the string index n and replacing Mmax with the maximum number of data strings for the Ntotal construction envelope.

The prior art of data inversion is illustrated in FIG. 16 (f) and (g). In the example, Nmax (as can be calculated by equation (1)) is 101 and the chain indices range from 0 to Nmax-1 (that is, from 0 to 100). Therefore, when solidifying from right to left (FIG. 16 (g)) along the x-axis, the string data set for the odd layer has a chain index of 40 (starting from n = 0 in the right boundary of construction envelope 345 in FIG. 16 (b)) is the same as the chain data set used for the even layer chain having the chain index n = 100-40 = 60. Therefore, the string indexes always start at zero at the limits of the left and right hand, but the inversion of the string data sets by the host computer as reflected in FIGS. 16 (f) and 16 (g) avoids the need to recalculate new string data for the odd layer from the object data. Instead, even layer data can simply be inverted and supplied to the microcontroller unit. In another example, the inversion process can be handled as a function of the value m of the memory index of the computer instead of the value n of the string index using equation (4). Thus, for example, by solidifying the odd layer (going from right to left) the string data for m = l can be calculated by taking the even layer data at m = Mmax-1-m (odd) = 39 (Mmax is the Total computer index values, which is 41, not the maximum index value that is 40). This last technique avoids the need to read string data for chains in which solidification does not occur and instead requires only reading those chains in which there is solidification, which by definition are those to which an m-value of computer memory index

As mentioned above, in some implementations of the systems described herein, a motor movement parameter is used, such as a number of engine stages to indirectly indicate when the linear solidification device 88 is in a location of the x axis corresponding to a particular linear scan or index string data, n. For a desired index value, n, the number of steps from the limit of the relevant construction envelope x axis, 343 or 345, can be calculated using the following formula:

(5) Phases = W (S) (n) (RPM) (F) / 60

where, Phases is the number of phases of the motor from the limit of the X axis of the construction envelope to the location where the line scan with the index value n is performed;

W is a ratio of motor phases for motor 76 per unit length in the direction of the x-axis in phases / mm;

S is the engine speed 76 in mm / second;

RPM is the rotation frequency of the rotating energy deflector in revolutions per minute; Y

F is the amount of facets in the rotating energy deflector.

The variable W can be considered as a "motor movement parameter" since it depends on a number of motor phases. As indicated above, W can be estimated from known mechanical relationships between the rotation speed and the transmission ratio of the engine 76 and the pulley diameters 82a and 82b. One method of estimating W is to determine the number of estimated phases required to traverse the length L of the x-axis of the construction envelope 342 based on said known mechanical relationships. However, due to thermal effects and other non-idealities, the estimated value of W may not be accurate. In cases where solidification is done bidirectionally with respect to the x axis (starting from the limits of the construction envelope 343 and 345), the error in W can cause misalignment between the even and odd layers because the calculated number of steps It will not correspond to the desired location of the x-axis that you think corresponds to the value of n used in equation (5). For example, if a construction process starts from the left to right direction along the x-axis direction, and W is too high, a given value of n will cause solidification to occur more to the right than desired. . As a result, the rightmost limit of the part will be more to the right than desired. If the solidification is reversed (from right to left), the number of steps corresponding to a given value of n will shift more to the left than desired. Therefore, when the resulting part is viewed from the same orientation as the one in which it was built (that is, with the side that was the left side during the formation positioned to the left of the side that was the right side during the formation ), the parts of the piece that solidified in the left-to-right direction will have an edge of the right hand that moves to the right in relation to the parts of the piece that solidified in the direction from left to right. The edge of the left hand of the parts of the solidified part in the right-to-left direction will shift to the left in relation to the solidified parts in the left-to-right direction. On the contrary, if the solidification starts from left to right and W is too low, seeing the resulting piece in the same orientation as the one in which it was built, the right edge of the solidified parts in the direction from left to right will be shifted to the left in relation to solidified parts

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in the direction from right to left, and the left edge of the solidified part in the direction from left to right will shift from the right when it solidifies.

As a result, in certain implementations, it is desirable to adjust the motor movement parameter (eg, W) based on the measurement data of the test piece. The measurement data of the test piece may comprise the length of a dimension or compensation space between two or more sections of the test piece. In certain cases where the data inversion method illustrated in FIG. 16 (f) and (g), a shift is created between the sections of identical layers that solidify in opposite directions along the x-axis. The offset is then used to adjust the value of W.

A method of preparing a test piece for use in determining the motor movement adjustment comprises forming a first series of layers of the test piece by moving the linear solidification device 88 in a first direction along the x-axis (by for example, from left to right) and perform linear scanning operations in the direction of the scan axis (y axis). A second series of layers is then formed by moving the linear solidification device 88 in an x-axis direction opposite to that used to form the first set of layers (for example, from right to left) and performing linear scanning operations in the scan axis (y axis direction). The test piece can have a variety of shapes, but in some examples a simple rectangular block shape is used. In other examples, and as illustrated in FIG. 25 (a) and 25 (b), a form of hemispherical test piece is used. In the formation of the test piece, an initial value of the motor movement parameter is specified which is believed to produce the correct length of the construction envelope 342 in the direction of the x-axis. In a preferred example, the motor movement parameter is a number of engine stages for the engine 76 that is estimated to correspond to the known length L of the construction envelope 342. From this data, a value can be calculated predicted by W.

As indicated in equation (5), if the motor movement parameter is wrong, the predicted value of W will also be wrong, which in turn will cause the number of motor phases (Phases) calculated from Equation (5) is wrong. The effects of said error in W can be exemplified by referencing the data in FIG. 16 (f). If a test piece is constructed using that data, the first series of layers will use all the data in FIG. 16 (f) and will be formed in the direction from left to right along the x axis. The second series of layers will be formed in the right to left direction along the x axis. As the data indicates, for the layers from left to right, the first linear scan that goes from left to right will be performed with the string index value n of 20. If the predicted value of W is greater than the actual value, The first linear scan will move further to the right from the boundary of the construction envelope on the left side 343 than desired, as will all subsequent linear scans. As a result, all layers from left to right (even) will shift to the right in relation to the desired position. When the solidification address is reversed and the data in FIG. 16 (g), the first chain in m = 0, n = 40 will move further to the left from the boundary of the construction envelope on the right 345 of the desired. Therefore, when the test piece is completed and viewed from the same orientation as its construction orientation, the first set of layers formed in the direction from left to right will move to the right in relation to the second set of layers formed in a direction from right to left. The change will produce a measurable displacement dimension.

The measured displacement dimension of the test piece can be used to correct the value of W used by the microcontroller according to equations (6) - (8):

(6) Step offset = A L * W

(7) Construction envelope length corrected in Phases = Phases (Expected) + Phase offset

(8) W corrected = Construction Envelope Length Corrected in Phases / L

where, AL is the measured displacement dimension (mm) between the first and second sets of test piece layers, and a positive value of AL indicates that the layers from left to right are shifted to the left with respect to the layers of right to left, while a negative value of AL indicates that the layers from right to left are shifted to the right in relation to the layers from right to left;

W is the original, predicted value of W (steps / mm);

L is the length of the construction envelope (mm);

Phases (Expected) is the original number of predicted steps to correspond to the envelope length L based on the motor rotation frequency, the transmission ratio and the pulley diameter, which is equivalent to W * L, where L is construction envelope length in mm; Y

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W corrected is the corrected value of W

The corrected W value can be used with equation (6) in subsequent parts creation processes. The above relationships can be generalized with respect to the construction instructions as follows: if solidification occurs in a first series of layers in a first direction and a second series of layers in a second direction (as opposed to the first direction), when the piece is visualized in an orientation (the vision orientation) that is the same in which the formation (orientation of the formation) was built, a value of W too low will cause the first set of layers to move in the second direction in relationship with the first set of layers, and the value of AL used in equation (7) will be positive. On the contrary, if the value of W is too high, the first set of layers will be compensated in the first direction with respect to the second set of layers, and the value of A L in equation (7) will be negative.

The relationship between "vision orientation" and "training orientation" can be better understood with an example. Each layer will solidify forming a series of linearly cured sections starting from a building envelope origin and ending at a construction envelope terminal point. A formation orientation can be selected by selecting an arbitrary coordinate system that will define an address from the origin to the terminal point, such as the "positive direction of the x-axis" or "left to right." "The" vision orientation "used to measure the displacement A should be the same as the orientation of the formation, so that when the object is visualized, the part of the solidified object in which solidification began (the origin) has the same directional relationship with the part of the solidified object with which the solidification ended (the terminal point).

In some examples, A L is measured using a calibrator with a minimum measuring capacity of 50 microns. In such cases, the compensation values A L of less than 50 microns cannot be measured, and the layers formed in one direction can be compensated with those formed in the other direction up to 50 microns. In some cases, it may be desirable to increase the accuracy of the part construction process by measuring smaller compensation values A L and adjusting a motor movement parameter (eg, W) accordingly. A suitable method for this purpose will be described below with reference to FIG. 25 (a) and 25 (b). In accordance with the technique, a generally hemispherical test piece is constructed. A first set of layers 504 is formed by solidifying the resin only when the solidification energy device 88 moves in a first (positive) direction along the x-axis (FIG. 16 (b)). A second set of layers 502 is then formed by solidifying the resin only when the solidification energy device 88 moves in a second (negative) direction opposite to that used to form the first set of layers 504. In FIG. 25 (a), layers 502 and 504 are seen looking in a direction perpendicular to the x-z plane (ie, along the scan axis or the y axis).

According to the method, the completed test piece is placed under a microscope and viewed along the z axis (height) so that the origin points of the layers are in the same relative positions along the x axis that during the formation process (that is, the points of origin of section 502 are further away in the positive direction of the x-axis than in the points of origin of section 504). Two circular sections 502 and 504 will be visible. If the motor movement parameter W is wrong, the inner circle 502 will not be concentric with the outer circle 504, although its diameters parallel to the x axis should be substantially collinear. In such cases, two displacements, An and Ar2, can be measured between the ends of the x-axis of each circular section 502 and 504. As shown in FIG. 25 (b), the location of the x-axis of section 502 furthest from the scan axis (y) can be subtracted from the location of the x-axis of section 504 that is furthest from the scan axis (y) to produce Ar 1 The location of the x-axis of section 504 that is closest to the axis and can be subtracted from the location of the x-axis of section 502 that is closer to the y-axis to obtain Ar2. If the motor movement parameter is set correctly, the value of An-Ar2 will be zero (or substantially zero). However, if the motor movement parameter is incorrectly set, An-Ar2 will not be zero. As mentioned above, in the example of FIG. 25 (a) and 25 (b) section 504 is formed only while the solidification energy device 88 moves in the positive direction of the x-axis, and section 502 is formed only while the solidification energy device 88 moves in the negative direction of the x axis. The negative value of An-Ar2 indicates that the motor movement parameter (for example, W) was set too low. Therefore, by constructing additional test pieces with increased values of W, the correct value (the one that produces Ar1 = Ar2) can be determined and introduced into the microcontroller for real part constructions (not test). Equations (6) - (8) can be used to calculate a corrected value of the motor movement parameter (Wcorrected) by substituting An-Ar2 for AL.

With reference again to FIG. 5C, the embodiments of a method for synchronizing a timer with the position of a scanning line within the construction envelope 342 will now be described. The method comprises activating a solidification energy source, such as source 90, which is in optical communication with a scanning device, such as a rotating energy deflector 92 or a linear scanning micro mirror. The scanning device deflects the solidification energy received from the solidification energy source 90, and the diverted solidification energy is received by a solidification energy sensor, such as sensor 324. In some examples,

a mirror such as the mirror 332 is provided to facilitate the transmission of diverted solidification energy from the scanning device to the sensor 324.

According to the method, the solidification energy sensor detects the reception of solidification energy and generates a detection signal that is transmitted to a system microcontroller. The reception of the solidification energy sensor corresponds to the start of a line scan operation. Then, a timer is initialized to a specified value (for example, zero) based on the reception of solidification energy by the sensor.

An example of the above synchronization method will be described with reference to FIG. 5C. As illustrated in the figure, in some examples, a solidification energy sensor 324, such as a light sensor, can be used to determine the location of the axis and the solidification energy supplied by the energy device linear solidification 88. In one example, a solidification energy sensor 324 is in optical communication with the rotating energy deflector 92 to receive solidification energy deflected therefrom. In another example, the solidification energy sensor 324 is located at one end of the housing 96 to indicate when the solidification energy projected in the direction of the axis and has reached the end or the beginning of the displacement in the direction of the axis and . According to the example, the solidification energy sensor 324 is positioned at a location corresponding to a maximum solidification energy position in the second direction (ie, at a location corresponding to the end of the path in the direction of the y-axis ). However, the sensor 324 may be located in other positions, but preferably it is in a place where the length of solidification energy that travels between the detected events is known. In FIG. 5C, the location of the mirror 332 and the sensor 324 together with the direction of rotation shown clockwise of the rotating energy deflector 92 make the detection of solidification energy by the sensor 324 correspond to the beginning of a linear scan operation.

According to these examples, a processor operatively connected to a clock (i.e., a 25 CPU clock) receives the signals from the solidification energy sensor of the sensor 324 and a timer operating in the clock units synchronizes with them, allowing to calculate a time elapsed between the pulses of solidification energy detected. The maximum scan length of the y axis is determined (for example, the length of the aperture 100 or a measured length of the solidification energy in the y-axis direction) and the travel speed of the solidification energy beam is calculated at the direction of the axis 30 and dividing the maximum length of displacement of the axis and by the elapsed time between impulses:

(9) s = 1 / At

where, s = speed of displacement of the solidification energy beam in the y axis (for example, cm / sec);

1 = maximum travel length (e.g., cm); Y

35 At max = elapsed time between solidification energy signals

sequentially generated by the solidification energy sensor (for example,

By synchronizing the clock with the reception of the solidification energy of the sensor and using that of speed (or a suitable average value), the position of the solidification beam in the direction of the y axis can be calculated:

40 (10) y = sAt

wherein, the position of the y = y axis of the solidification energy beam along the solidifiable material in relation to the starting point of the y axis (for example, cm);

s = speed of the solidification energy beam travel of the formula (1); Y

At = time elapsed since the last solidification energy signal of the sensor.

A linear solidification controller (for example, as implemented in a microcontroller unit) operatively connected to the solidification energy source 90 can selectively activate and deactivate the solidification energy source 90 to cause solidification energy to be supplied only when the linear solidification device 88 is in an x location, and in the solidifiable material corresponding to a point in one of the strips 304j shown in FIG. 16. Using 50 formulas (9) and (10), the linear solidification controller can receive data indicative of the axis position and solidification energy. A linear encoder can provide the linear solidification controller with the location information of the x-axis (for the linear solidification energy device 88), allowing the controller to determine the desired y-axis profile at the determined location of the x-axis from data of objects like the one in FIG. 16 (a). As mentioned above, object layer data can also be converted into a plurality of sets of data strings so that each plurality corresponds to a given layer and position along the construction axis (z axis) . According to these examples, each set of data strings includes a

the direction

detected

sec)

last energy value of

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plurality of time values, each of which defines a time at which the activation state of the solidification energy source 90 changes. Preferably, the time values are defined relative to a zero time that is restarted upon receipt. of a synchronization solidification energy generated when the sensor 324 receives solidification energy, as also described previously. As mentioned above, in some examples, the zero time of a CPU counter is set at the leading edge 1104a of the synchronization sensor signal received by the sensor 324 (FIG. 24).

With reference again to FIG. 16 (a), each strip 304j corresponds to a continuous solidification region in the direction of the y-axis. However, depending on the object being created, this may not be the case. Some of the strips 304j may be discontinuous, thereby defining sections not connected along the y axis for a given location of the x axis. In some examples, a solidification energy modulator (such as a laser diode modulator in the case of a laser diode solidification energy source 90) is provided to selectively activate the solidification energy source 90. In other examples , the solidification energy source 90 remains constantly activated and the transparency of the selected locations in a flexible mask is manipulated to allow solidification energy to pass through locations in the solidifiable material where solidification is desired.

With reference to FIG. 21, a method for forming a three-dimensional object using a linear solidification device such as the linear solidification device 88 will be described below. In a preferred embodiment, the method is embodied in a set of computer-readable instructions in a computer readable medium that can be run by a computer processor.

According to the embodiment, at the beginning of an object creation process, the positions x, y, z are initialized at their initial positions with their indexes i, j and k set to 0, that is, x0, y0 and z0 ( step 1002). In step 1004, the z-axis index (k) is increased by one and the object data for the first segment of the object in z (1) is read (step 1006). The index of the x-axis (i) is increased by one in step 1008 and the index of the y-axis (j) is increased by 1 (steps 1008 and 1010). In step 1012, it is determined whether the location x (i), y (j) on the exposed surface of the solidifiable material corresponds to a region of the object (i.e., a location where solidification is desired based on the object data ). If it does, solidification energy is provided to the location in step 1014. As previously explained, in some implementations, step 1014 involves selectively activating or deactivating the solidification energy source 90. In other implementations, the step 1014 involves selective activation of the location x (i), and (j) in a flexible mask to allow or prevent solidification energy from passing through it when the solidification energy source 90 remains continuously activated.

If the determination made in step 1012 indicates that no solidification should occur at location x (i), and (j) on the surface of the solidifiable material, the control proceeds to step 1016 where it is determined whether the maximum position has been reached of the y-axis (that is, the limit of the construction envelope in the direction of the y-axis). If it has not been reached, the position index of the y-axis (j) is increased by one, and the control returns to step 1010. If the maximum position of the y-axis has been reached, the control is transferred to step 1017 in which the Y-axis index (j) is reset to 0. In step 1018, it is determined whether the maximum position of the x-axis has been reached (ie, the limit of the construction envelope in the direction of the x-axis). Otherwise, the control is transferred to step 1008, where the index of the x-axis is increased by one. If the maximum position of the x-axis has been reached, the control is transferred to step 1019, where the position index of the x-axis (i) is reset to 0. In some examples, once the maximum position of the x-axis is reached , the linear solidification device 88 will travel in the opposite direction along the x-axis to solidify another sheet of the object (bidirectional solidification), while in other examples, the linear solidification device 88 will move in the opposite direction without performing any solidification and then solidify the next sheet (unidirectional solidification).

In step 1020, it is determined whether the final segment of object data (zmax) has been reached. If you have done so, the method ends. If the final sheet has not been reached, the control returns to step 1004, and the z-axis index (k) is increased by one so that the object data can be processed for another cut. The process is repeated until the last sheet has solidified.

With reference to FIG. 22 and 23, another method for manufacturing a three-dimensional object using a linear solidification device such as the linear solidification device 88 (or the previously described variants of device 88) is described. According to the method, three-dimensional object data is provided in step 1042. The data can take a variety of forms such as CAD / CAM data, STL data or other data that define the shape of the object in three-dimensional space. In step 1044, the data is laminated in several Zmax object layer data sets, where each object layer data set corresponds to a particular layer identified by a value of the layer z index that varies in value from 0 to Zmax-1 A graphic representation of said laminate is exemplified in FIGS. 14 and 15. However, the actual rolling method comprises subdividing the data of three-dimensional objects along a specified axis. In preferred examples, the axis along the

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which subdivision is made corresponds to the construction axis used in the solidification process. Such data segmentation techniques are known to those skilled in the art and generally involve identifying the intersection of data from three-dimensional objects (such as that defined by STL files) with a cut plane defined by a construction axis coordinate. The intersection will define the contours of the object for the sheet.

In step 1046, Mmax sets of linear scan data are created for each object layer data set. Each layer has its own value of Mmax, which refers to the total number of linear scans needed to create a piece. Mmax will also be the maximum value of the m value of the computer's memory index for the layer because it represents the number of data storage locations required to store the number of data string sets that include solidification data of objects in the particular layer. . On the contrary, the entire construction envelope 342 (FIG. 16 (b)) can have a different maximum number of data chains (Nmax) associated with it representing the maximum possible number of linear scans that could be performed in the envelope of construction 342.

In step 1048, the linear solidification device 88 is moved to an initial position within the x-plane, and which can be defined by the position of an end-of-travel sensor (EOT) 346 (FIG. 16 (b)). The initial position preferably moves from the left boundary 343 of the construction envelope 342 over a specified compensation distance 5l. In some examples, the left boundary 343 defines a point x0 origin of the x axis. The travel distance 5l can be specified as a motor movement parameter, such as a number of motor stages, in which case the motor stages can be used to determine when the linear solidification device has reached the left limit 343.

In step 1050, the motor 118 (FIG. 5A and 5C) is activated to begin the rotation of the rotating energy deflector 92. The layer index (z) is set to zero to indicate that the object creation process is at starting point

In step 1054, the linear scan data for the layer corresponding to the current value of the layer index (z) is loaded into the microcontroller unit that is used to operate motor 118 and motor 76 and which is also used to change the state of potentiation of the solidification energy source 90. The linear solidification device 88 moves through the travel distance 5 (which will be 5l or 5r depending on the direction of movement of the x-axis) to reach the limit 343 or 345 of the building envelope. During the movement of the linear solidification device 88 through the deviation distance 5, the speed of the linear solidification device 88 will preferably reach a substantially constant value. In certain implementations, the linear scan data is corrected to take into account variations in the scanning speed along the scan axis, for example, using equation 3 (b) or 3 (c) described above. .

In step 1058, the memory index value of the computer m is set to zero. As explained above, the memory index of the computer m is an index used to store those sets of string data that have solidification data of objects therein. In step 1060, the string index n is also set to zero.

In step 1061, the microcontroller reads the set of string data stored in the current value of the computer memory index m. The string data set preferably includes a string index value (n) (see FIG. 16 (d), (f) and (g)), and in step 1062 the string index value provided in the string data set for the current value of m is compared with the current value of n. When the values are the same, it indicates that solidification will occur at the position of the x-axis corresponding to the current chain index value (n). When the values are not the same, it indicates that no solidification will occur at the position of the x-axis corresponding to the value of the current chain index (n), so it is not necessary to read data for that chain.

When n = m in step 1062, control proceeds to step 1064. In step 1064, a scan axis synchronization operation is performed before the start of a line scan operation. In one example, the solidification energy source 90 is briefly driven to cause the sensor 324 (FIG. 5C) to generate a synchronization solidification energy sensor signal, which indicates that the rotational position of the rotating energy deflector 92 corresponds to the limit of the scan axis of the construction envelope. A timer is then initialized (such as one programmed in software) (for example, reset to zero) and started (step 1066). The microcontroller unit compares the timer value with the time values stored in the current set of string data (defined by the current value of the computer memory index m) to determine when to change the activation status of the power source solidification 90 (step 1068). As previously described, in the example of FIG. 24 the solidification energy source 90 is driven in a fixed delay time (A1) relative to the pulses of the motor 118 used to drive the deflection of rotating energy 92 to perform the synchronization. This synchronization pulse can occur at each chain index location (n) regardless of whether it is a location where solidification will occur.

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Alternatively, it can be done only for those locations where solidification will occur. As also described above, the solidification power source 90 can be driven at a fixed time in relation to a clock cycle of the CPU instead of driving with respect to the pulses of the motor 118 for synchronization. In one example, a dynamic calibration process of the type described above is used in which the fixed time is determined by dynamically adjusting the timing of the synchronization energy pulse in relation to the CPU clock until the sensor 324 indicates that it has received the energy boost In such cases, a delay time A1 relative to the pulses of the motor 118 can be used as a starting point for the dynamic adjustment process.

The timing of the timer to a rotating position of the rotating energy deflector 92 will be further described with reference to FIG. 24. Once the timer has been initialized, the solidification power source 90 is turned off until the current object data chain indicates that it must be activated. Due to the delay of the system, such as the one that involves receiving and processing the signals of the synchronization sensor 324 and generating solidification power source output signals, there may be a delay between the reception of the microcontroller from an ascending edge 1104a of a signal synchronization sensor 324 and shutdown of solidification power source 90.

Sensor 324 (FIG. 5C) has a detection length that can be traversed if the solidification energy source is left on during the period in which it is in optical communication with the mirror 332. As a solidification energy beam passes through the mirror 332 from the top down will pass the sensor 324 from the bottom up. However, once the solidification energy reaches the bottom of the mirror 332, it will begin to make contact with the solidifiable material and solidify it. Preferably, the solidification energy source 90 is deactivated before it leaves the sensor detection area 324 or the mirror area 332 during a synchronization operation. Otherwise, the solidification energy would make contact with and solidify the solidifiable resin earlier than indicated by the chain data. In some examples, the delay between the reception of the rising edge of the solidification sensor input signal 324 and the deactivation of the solidification energy source 90 occurs within a delay time A2 that is not more than about 400 nanoseconds, preferably no more than about 300 nanoseconds, more preferably no more than about 250 nanoseconds, and even more preferably no more than about 200 nanoseconds.

In preferred examples, the delay time A2 is less than the time required for the solidification energy to traverse the entire detection length of the sensor 324. The time required for the solidification energy to traverse the entire length of the sensor 324 can be calculated from as follows:

(11) time = (60sec / min) (LS / (LBExRPMxF))

where, Ls = linear distance of the sensor detection area;

Lbe = length of the construction envelope in the direction of the scan axis (y) (i.e.

the linear length of a full scan);

RPM = rotational speed of the rotating energy deflector 92 (revolutions / minute); Y

F = number of facets in the rotating energy deflector 92.

With reference again to FIG. 22, when the line scan operation is completed, the current value of the computer memory index m is compared with the maximum index value (Mmax-1) for the current layer (step 1070). If m is less than Mmax-1, the layer is not complete. In that case, the control proceeds to step 1072 and the value of the memory index of the computer m is increased by one. The string data set for the new value of m is read in step 1076. In step 1078, the value of the string index n is increased by one and then the rotating energy deflector 92 turns to the next facet 94 ( a) - (f). Control returns to step 1062.

During step 1062 if the string index value n that is stored in the string data set for the current value of m is not equal to the current value of the string index value n, then solidification will not occur in the position of the x axis corresponding to the current value of the string index n. In that case, the control is transferred to step 1074 to determine if the last Nmax-1 chain has been reached. If it has been reached, control is transferred to step 1080 (FIG. 23). Otherwise, the control is transferred to step 1078 where the value of the string index n is increased again by one. In step 1070 if the current value of the memory index m has reached the maximum layer value Mmax-1, no further solidification will occur in the current layer and the control proceeds to step 1074.

As mentioned above, in some examples a microcontroller is used to control the operation of the solidification energy source 90 on the basis of the data of the object shape and can also regulate the movement of the construction platform (by example, construction platform 43 in FIG. 1-2 or construction platform 354 in FIG. 19). Many commercially available microcontrollers use what is known as "interruptions" to perform

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tasks such as USB communications, memory update and reading of peripheral devices. During an interruption, the currently executed task stops so that one of these other tasks can be performed. However, in those examples that use string data comprising time values to represent a three-dimensional object, an interruption will alter the synchronization of the CPU timer with the position of the rotating energy deflector (or the tilt angle of a scanning micro mirror. laser) and potentially distort the three-dimensional object. In such examples, it is preferable to cancel software and / or hardware interruptions during a line scan operation. In one example, a program is stored in the microcontroller that causes interrupts to be disabled when the method of FIG. 22-23 is between steps 1062 and 1082. Interruptions can be enabled when the method reaches step 1084.

In step 1074, when the chain index value n reaches the maximum chain index value Nmax-1, the processing of the current layer is completed. The control then proceeds to step 1080 to move the linear solidification device 88 through the travel distance 5. If the linear solidification device 88 processes the current layer moving from left to right (when construction envelope 342 is viewed from above), distance 5 in step 1080 will be 5r. Otherwise, it will be 5l.

In step 1082, the current value of the layer index (Z) is compared with the maximum layer index value (Zmax-1). If the last layer has been completed, the construction ends. Otherwise, the layer index is increased by one (step 1084). In step 1086, a new amount of non-solidified solidifiable material is provided between the previously solidified layer and the rigid or semi-rigid solidification substrate 68. In the case of the systems shown in FIG. 1-4 and 6-8, this could be done, for example, by moving the construction platform 43 down in a solidifiable material supply, which would produce a space between the last solidified layer and the substrate 68 in which fresh material can flow not solidified. In the case of systems such as those shown in FIG. 19 and 20, the construction platform 356 can be moved upwards and new solidified non-solidified material can be added to the container film assembly 205 or to one of the other container structures described above.

In step 1088, the linear scan data (i.e., string data sets) corresponding to the new z-layer index value is loaded into the microcontroller unit. In step 1090, the direction of travel of the linear solidification device 88 along the direction of the x-axis is reversed. The linear solidification device moves through the applicable travel distance 5l or 5r until the applicable construction envelope limit 343 or 345 is reached. The control then returns to step 1058 in FIG. 22 to begin the process of solidification of the new layer.

With reference to FIG. 17-18, an alternative embodiment of a system for making a three-dimensional object is depicted. The system comprises a solidification substrate assembly 62 that is substantially similar to solidification substrate assembly 62 of FIG. 7-13. In this embodiment, however, the linear solidification device 88 has been replaced by the linear solidification device 308. Although FIG. 17-18 represent the linear solidification device 308 with the solidification substrate assembly 62 of FIG. 7-13, it can also be used with the embodiment of the solidification substrate assembly 62 shown and described with respect to FIG. 3 and 7 using a curved, stationary, rigid or semi-rigid solidification substrate 68. In FIG. 17-18, film assembly 205 is again provided (film 224 is not visible in FIG. 17 and 18).

In the example of FIG. 17-18, the linear solidification device 308 comprises an array of light projection elements such as an arrangement of laser elements or light emitting diode elements 310ü-310max. In a preferred embodiment, each of these elements is "scalable in gray", so that the duration of activation of each element at a given location in the x-plane, and is the same while each element projects an intensity of individually controllable light. The linear solidification device 308 may comprise a single row of light projection elements 310ü-310max and may also include several rows of light projection elements arranged in the length direction (x axis) of the solidification substrate assembly 62. In some examples, at least two rows of light projection elements are provided with the rows arranged in the direction of length (x axis) and their respective light projection elements staggered in the direction of width (y axis) to create a zigzag pattern.

In contrast to the linear solidification device 88, at a certain position along the longitudinal direction (x-axis) of the solidification substrate assembly 62, the linear solidification device 308 can selectively and simultaneously solidify locations throughout the entire envelope direction of the y axis. Each element of the light emitting elements 3100-310max projects a corresponding pixel of solidification energy over a corresponding location and of the solidifiable material (the location of the x-axis depends on the position of the linear solidification device 308 which is variable). Therefore, the energy is not "scanned" in the direction of the axis and as with linear solidification device 88. In addition, the object data can be provided as volumetric pixels ("voxels") each having their own location x and y , and the associated solidification depth in the z-axis direction because the gray scale feature allows controllable intensities

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individually, which in turn can provide individually controllable cure depths. The grayscale value represents a total exposure for the pixel (in which the total exposure for the pixel is expressed as follows:

(12) Total Exposure = I I dt

where, I is the intensity of the solidification energy supplied (for example, Watts / pixel)

and the integration takes place during the period of exposure time, At.

In some examples, the gray-scale output value can be used to control the result of the linear solidification device to provide full intensity, no result, or intermediate variations. In processes that use a fixed exposure time per pixel, the linear solidification device can reduce the amount of electromagnetic radiation (e.g. intensity, I) to which the solidifiable material for each pixel is exposed during the specified exposure time.

In a preferred embodiment, the linear solidification device 308 moves continuously in the direction of the x-axis since the solidification energy pattern is generally provided, or preferably, substantially linear in the direction of the y-axis. Depending on the profile of the object being constructed, the solidification energy pattern defined by the linear solidification device 308 may change as different locations are reached in the direction of the length (x-axis).

The use of gray scalable light emitting elements 3100-310max allows the use of voxelized object data to represent the three-dimensional object being constructed. The voxel data can be considered a collection or set of data that represents volumetric pixels. The voxel data can be organized in a voxel bitmap pattern that includes a gray scale value for each pixel and / or an exposure time. The voxelized bitmap can be considered an organized collection of individual voxels, each voxel has its own depth that is independent of the other voxels. Although voxels can be organized in a bitmap, each voxel is treated individually and has its own cure depth (which can be determined by the exposure time and / or intensity value assigned to each voxel) to determine the geometry of each voxel independently of any other voxel data. The object can be formed using voxel data where each voxel can be created in the solidifiable material by exposing the exposed surface of the solidifiable material to obtain a particular depth of cure (usually determined by the gray scale value and / or the exposure time) and therefore creates the three-dimensional voxel in the solidifiable material. Each voxel can be generated individually, in a group or subset (for example, more than one voxel), or as a set of voxel data (for example, all voxels at once).

When a voxelized construction process is used, each voxel can have its own thickness (for example, solidification depth) that is controlled by the gray scale value. However, sheet object data such as that described with respect to FIG. 15 to carry out the operation of arrays of linear light emitting devices comprising the linear solidification device 308. A control unit (not shown) receives object data in the desired format and directs the activation of each element. Light projection 3100-310max.

While the grayscale intensity can be expressed as an integer in a reference scale (for example, 0 ... 255), the intensity value can also be compensated or adjusted before being sent to the linear solidification device 308 , or it can be compensated or adjusted in the linear solidification device 308, or both. For example, when the solidifiable material has a minimum intensity threshold that is required for polymerization or partial polymerization, the intensity of the "off or zero (0) value (for example, Brightness and / or" on "time) can be determined in function of the specific minimum intensity threshold for the particular solidification material A zero value for the intensity does not necessarily imply that the energy supplied by the linear solidification device 308 is really zero.In a usual case, a low level of brightness may correspond at zero intensity (0).

Intensity ranges from 0 to 255 are suitable for examples when using an 8-bit system to determine the intensity. However, systems that have more or less resolution for intensity can be used. Examples may include a 4-bit system or a 16-bit system. In addition, the exposure time of electromagnetic radiation can have a wide range, for example, from 1 millisecond to 100 seconds. It should be noted that the time interval is simply an example and is not limiting since the "on time" for electromagnetic radiation can depend on other variables such as the minimum switching time of the pattern generator, the intensity of the radiation electromagnetic, the minimum effective time of the solidifiable material and the intensity of radiation for solidification, the speed of movement of the construction platform 43 and other factors.

The solidification process of the solidifiable material with the linear solidification device 308 or the linear solidification device 88 can occur in discrete stages with the formation of discrete object layers or without the use of a stratified forming process. In particular, a continuous construction process can be used in which the construction platform 43 moves throughout the entire

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Building process. Even with continuous construction processes, due to possible interruptions of electromagnetic radiation, slight formation of the interface layer could still occur. However, such interface formation can be minimized or even completely eliminated.

When continuous construction processes are used, the structural "steps" that sometimes appear in the outer contours of objects constructed with layer processes can be minimized. In continuous construction processes, the three-dimensional object can solidify or grow in the main construction direction (usually in the Z direction) without interrupting the supply of electromagnetic radiation during an irradiation phase and, optionally, during the entire construction process. The corresponding continuous growth of solidifiable material in the main construction direction (Z) during an irradiation phase can thus proceed to a degree that exceeds a usual hardening depth of conventional layering solidification and is predetermined by the used radiation supply electromagnetic and / or a polymerizable material used.

Through continuous independent operation of the layer, it is even possible to specifically influence and control a current hardening depth of the solidifiable material. An adjustment of the speed of the support plate that supports the object that is generated moving away from the construction surface and an adjustment of the intensity of irradiation of the pixels (gray or color value), respectively alone or in combination, are particular means to control the depth of hardening

The present invention has been described with reference to certain exemplary embodiments thereof. Exemplary embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is defined by the appended claims and their equivalents, rather than by the preceding description. Other embodiments that are not part of the claimed invention are provided in the following paragraphs:

An apparatus for manufacturing a three-dimensional object from a solidifiable material, comprising: a mobile solidification energy source in a first direction, in which the solidification energy source selectively projects solidification energy in a second custom direction that moves in the first direction; a rotating energy deflector movable in the first direction and rotating in a rotation plane that is substantially perpendicular to the first direction, in which the rotating energy deflector is in optical communication with the solidification energy source and when the energy source solidification projects solidification energy in the second direction, the rotating energy deflector deflects the solidification energy towards the solidifiable material, and the deviated solidification energy solidifies the solidifiable material.

2. The apparatus of embodiment 1, wherein when the solidification energy source projects solidification energy in the second direction, the deflected light scans the solidifiable material in a scanning direction.

3. The apparatus of embodiment 1, in which the solidification energy source moves in the first direction at a first speed, the diverted solidification energy scans the solidifiable material in the scanning direction at a scanning speed, and the scanning speed is at least 1000 times the first speed.

4. The apparatus of embodiment 1, in which the rotating energy deflector is a mirror having one or more facets, and each facet has a rotating position in which it is in optical communication with the laser diode.

5. The apparatus of embodiment 1, further comprising at least one lens between the rotating energy deflector and a source of the solidifiable material, in which the lens is coated with an anti-reflective coating such that the lens transmits at least one 95% of incident light having a wavelength that varies from approximately 380 nm to approximately 420 nm.

6. The apparatus of embodiment 5, wherein the anti-reflective coating is a MgF2 coating.

7. The apparatus of embodiment 5, wherein the at least one lens is first and second F-Theta lenses, the first F-Theta lens is between the rotating light deflector and the second F-Theta lens, the first F-Theta lens has an incident face and a transmitting face, the second F-Theta lens has an incident face and a transmitting face, and the radius of curvature of the first transmitting face of the F-Theta lens is smaller than the radius of curvature of the transmitting face of the second F-Theta lens.

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8. The apparatus of embodiment 1, further comprising a collimation lens between the solidification energy source and the rotating energy deflector.

9. The apparatus of embodiment 8, in which the collimation lens is formed of BK-7 optical glass.

10. The apparatus of embodiment 8, wherein the collimation lens has an effective focal length of about 4.0 mm to about 4.1 mm.

11. The apparatus of embodiment 1, further comprising a solidification energy sensor in optical communication with the rotating energy deflector.

12. The apparatus of embodiment 11, further comprising a mirror in optical communication with the rotating energy deflector and the solidification energy sensor, in which when the solidification energy source projects solidification energy in the second direction During a synchronization operation, the deflected light is reflected outside the mirror and transmitted from the mirror to the sensor.

13. The apparatus of embodiment 11, further comprising a neutral density filter that is positioned to receive and filter the light transmitted to the solidification energy sensor.

14. The apparatus of embodiment 11, in which the apparatus includes a construction envelope, the construction envelope is a part of the solidifiable material in which the projected solidification energy can deviate from the rotating energy deflector, the rotational position of the rotating light deflector in the rotation plane defines a position of deviated solidification energy within the construction envelope along the scanning direction axis, and when the solidification energy sensor receives deviated solidification energy, the position Rotation of the rotational energy deflector corresponds to a construction envelope limit.

15. The apparatus of embodiment 11, wherein the projected solidification energy is diverted from the rotating energy deflector to create solidification energy scan lines in the solidifiable material along a scanning direction axis, and the reception of sensor energy deflected by the solidification energy sensor corresponds to a limit position along the direction of the scan axis.

16. The apparatus of embodiment 1, further comprising a solidification energy source controller that selectively activates the solidification energy source based on the shape information about the three-dimensional object.

17. The apparatus of embodiment 16, wherein the shape information comprises object data corresponding to a plurality of object cross-section strips, each object cross-section chain has a length defining a longitudinal direction and a width that defines a width direction and the plurality of strips are arranged in width along the width direction.

18. The apparatus of embodiment 17, wherein the solidification energy source has an activation state, the solidification energy source controller selectively changes the activation state of the solidification energy source according to a plurality of sets of data strings, each plurality of sets of data strings corresponds to a layer of the three-dimensional object, and each set of data strings within each set of data strings corresponds to a cross-sectional strip of the object and includes a plurality of numbers that define a time when the activation state of the solidification energy source changes.

19. The apparatus of embodiment 1, wherein the solidification energy source is a laser diode that projects light having a wavelength of approximately 380 nm to 420 nm.

20. The apparatus of embodiment 19, wherein the laser diode has an output power of at least about 300 mW.

21. The apparatus of claim 19, wherein the laser diode has a beam divergence of at least about 5 milliadianes.

22. The apparatus of embodiment 1, wherein the solidification energy source is a first solidification energy source, and the apparatus further comprises a second source

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of solidification energy moving in the first direction, in which the second solidification energy source selectively projects solidification energy in the second direction while moving in the first direction.

23. The apparatus of embodiment 22, further comprising first and second prisms, where when the first prism receives solidification energy transmitted from the first solidification energy source and the second prism receives solidification energy transmitted from the second solidification energy source, the first prism is between the first solidification energy source and the rotating energy deflector, and the second prism is located between the second solidification energy source and the rotating energy deflector.

24. The apparatus of embodiment 23, further comprising a first collimator located between the first solidification energy source and the first prism and a second collimator located between the second solidification energy source and the second prism.

25. The apparatus of embodiment 1, wherein the rotating energy baffle rotates at a rotation speed of about 1,000 RPM to about 10,000 RPM.

26. The apparatus of claim 1, further comprising a source of the solidifiable material defining a construction envelope, a first displacement region and a second displacement region, in which during a three-dimensional object construction operation, the three-dimensional object it is constructed in the building envelope but not in the first displacement region or in the second displacement region; an end-of-path sensor in the first displacement region to detect an end-of-travel position of the solidification energy source in a direction away from the building envelope.

27. The apparatus of embodiment 26, wherein the solidification energy source selectively projects solidification energy in accordance with linear scan data sets, wherein each linear scan data set corresponds to a three-dimensional object layer and comprises a plurality of sets of data strings, each set of data strings has a string index ranging from a minimum value to a maximum value and a plurality of time values, each time value corresponds to a change event of solidification source activation status, and each minimum chain index value corresponds to a boundary between the first displacement region and the construction envelope.

28. The apparatus of embodiment 27, wherein each linear scan data set has a maximum chain index value corresponding to an edge between the second displacement region and the construction envelope.

29. The apparatus of embodiment 27, further comprising a host computer and a microcomputer, in which the host transmits the string data sets corresponding to each set of linear scan data to the microcomputer, and the microcomputer includes a Central processing unit programmed to project energy in the second direction selectively according to the chain data sets and move the solidification energy source in the first direction.

30. The apparatus of embodiment 29, wherein the microcomputer is programmed to prohibit interruptions during layer solidification operations.

31. A method of making a three-dimensional object from a solidifiable material, comprising: moving a solidification energy source in a first direction; Progressively expose parts of solidifiable material to solidification energy in a second direction along an exposed surface of the solidifiable material as the solidification energy source moves in the first direction.

32. The method of embodiment 31, in which the first direction is substantially perpendicular to the second direction.

33. The method of embodiment 31, wherein the step of progressively exposing portions of solidifiable material to solidification energy in a second direction along an exposed surface of the solidifiable material when the solidification energy source moves in The first address comprises performing a series of line scanning operations, and the method further comprises synchronizing a timer at the beginning of each line scanning operation.

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34. The method of embodiment 33, further comprising providing a solidification energy sensor in optical communication with a solidification energy source, in which the step of synchronizing a timer at the beginning of a scanning operation comprises configuring the timer at a specified time value in response to solidification energy detection by the solidification energy sensor.

35. The method of embodiment 33, wherein the step of gradually exposing a part of the solidifiable material to solidification energy along the second direction comprises selectively exposing a part of the solidifiable material to solidification energy along the second address according to object data comprising a plurality of string data sets, wherein each string data set comprises a plurality of time values that define a solidification source activation state switching event, and each time value is equal to a time elapsed after the start of a line scan operation.

36. The method of embodiment 35, wherein each set of chain data further comprises a chain number, and each chain number corresponds to a location within a building envelope part of a solidifiable material source.

37. The method of embodiment 33, wherein the step of synchronizing a timer at the start of a line scan operation comprises projecting solidification energy to a rotating energy deflector driven by a motor energized by frequency energy pulses constant over a specific time relative to each impulse occurring.

38. The method of embodiment 37, wherein the step of synchronizing a timer at the start of a line scan operation comprises projecting solidification energy to a rotating energy deflector for a detection pulse of about 2 to about 6 milliseconds

39. The method of embodiment 38, wherein the step of synchronizing a timer at the start of a line scan operation comprises stopping projecting solidification energy towards the rotating energy detector within a delay time after A synchronization sensor detects solidification energy.

40. The method of embodiment 39, wherein the delay time is not more than about 400 nanoseconds.

41. The method of embodiment 33, wherein the step of synchronizing a timer at the start of a line scan operation further comprises dynamically calibrating a pulse of synchronization energy to a processor clock.

42. The method of embodiment 41, wherein the step of dynamically calibrating a pulse of synchronization energy comprises a pulse of transmission energy in a plurality of test times relative to the processor clock and determining a clock time of the processor in which a pulse of transmitted energy produces a solidification energy sensor signal.

43. The method of embodiment 31, further comprising:

providing first and second identical three-dimensional object layer data corresponding to adjacent layers of solidifiable material used to form the three-dimensional object;

subdivide the first and second identical three-dimensional object layer data into respective first and second pluralities of object cross-section strips, in which each object cross-section strip into the first plurality of object cross-section strips has a set of strip data and a corresponding computer memory index value n (0) varying from 0 to one less than the total number of strips in the first plurality of object cross-section strips (Ntotal), each strip in the second plurality of object cross-section strips has a set of string data and a corresponding computer memory index value n (1), and strip data corresponding to each respective value of n (1) for the second plurality of object cross-section strips equal to the string data for the first plurality of object cross-section strips corresponding to the memory index value of the computer n (0) equal to one less than Ntotal minus the respective value of n (1).

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44. The method of embodiment 31, further comprising:

provide data of three-dimensional objects representative of the three-dimensional object; laminating three-dimensional object data to define a plurality of three-dimensional object layer data sets; provide a construction envelope distance in the first direction, in which the construction envelope distance in the first direction corresponds to a value of a motor movement parameter of a motor that is activated to move the source of energy source from solidification in the first direction; adjust the value of the motor movement parameter corresponding to the distance of the construction envelope based on the measurement data of the test piece.

45. The method of embodiment 44, further comprising: forming a first series of layers of the test piece, where each layer in the first series of layers is formed by moving the solidification energy source in the first direction of testing and progressively exposing parts of the solidifiable material to the solidification energy in the second direction along an exposed surface of the solidifiable material as the solidification energy source moves in the first direction; forming a second series of layers of a test piece, where each layer in the second series of layers is formed by moving the solidification energy source in a third direction opposite to the first test direction and gradually exposing parts of solidifiable material to energy solidification in the second direction along an exposed surface of the solidifiable material as the solidification energy source moves in the third direction; measure a displacement distance between the first series of layers and the second series of layers; and adjust the value of the motor movement parameter corresponding to the distance of the construction envelope as a function of the measured displacement distance between the first series of layers and the second series of layers.

46. The method of embodiment 31, wherein: the step of progressively exposing portions of solidifiable material to solidification energy in the second direction along an exposed surface of the solidifiable material when the solidification energy source moves in the first direction it comprises diverting solidification energy from a rotating energy deflector that has a number of facets F towards the solidifiable material, the three-dimensional object has a desired length L along the first direction at a specified position of the construction axis The step of gradually exposing parts of the solidifiable material to the solidification energy in a second direction along an exposed surface of the solidifiable material when the solidification energy source moves in the first direction comprises performing several line scanning operations. corresponding to the axis position of specified construction, and each line scan operation corresponds to a location along the first address and the number of line scan operations is represented by the following formula: n = (L / S) * (RPM / 60) * F, where n = number of line scan operations; L = desired length of the object at the specified position of the construction axis (mm); S = speed of movement of the solidification energy source in the first direction (mm / sec); RPM = rotational frequency of the rotating energy deflector (revolutions / minute); and F = number of facets in the rotating energy deflector.

47. The method of embodiment 46, wherein each line scan operation comprises selectively changing the activation state of the solidification energy source according to a set of chain data comprising one or more time values , each time value defines a solidification source activation state switching event, and each time value is equal to a time elapsed after receipt of a synchronization signal by a solidification energy sensor.

48. The method of embodiment 31, wherein the step of progressively exposing portions of solidifiable material to solidification energy in a second direction along an exposed surface of the solidifiable material when the solidification energy source moves in A first address is controlled by a microcontroller that has an interruption function, and the interruption function is deactivated during the progressive exposure step.

49. A method for calibrating the length of a construction envelope along a first direction, comprising: specifying a value of a motor movement parameter corresponding to the length; constructing a test piece by solidifying a solidifiable material in a first series of layers of the test piece along a first direction of length and solidifying the solidifiable material in a second series of layers of the piece of

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test along a second direction of length opposite the first direction of length, in which the test piece has at least one displacement dimension along the first direction of length defined by the first series of layers and the second series of layers; measure a length of at least one displacement dimension; and adjust the value of the motor movement parameter based on at least one compensation dimension length.

50. The method of embodiment 49, in which the test piece is a hemisphere, the first series of layers defines a first section having a first diameter when the test piece is viewed from above, the second series of layers defines a second section that has a second diameter when the test piece is viewed from above, the second diameter is larger than the first diameter, and the at least one compensation dimension is two displacement dimensions between the first and the second section .

51. The method of embodiment 50, wherein the step of measuring the two displacement dimensions comprises viewing the test piece from above with a microscope.

52. The method of embodiment 49, wherein the step of solidifying a solidifiable material in a first series of layers along the first length direction comprises progressively solidifying the solidifiable material along a third direction while moving a source of solidification energy along the first direction of length.

53. The method of embodiment 49, wherein the step of solidification of the solidifiable material in a second series of layers of the test piece along a second direction opposite the first direction comprises progressively solidifying the solidifiable material to along the third direction while the solidification energy source moves along the second direction of length.

54. An apparatus for manufacturing a three-dimensional object from a solidifiable material, comprising: a mobile solidification energy source in a first direction, in which the solidification energy source can be selectively activated while moving in the first direction to solidify a substantially linear section of the solidifiable material that extends along a second direction; a solidification substrate assembly comprising a transparent, rigid or semi-rigid solidification substrate, in which when the solidification energy source moves in the first direction, the solidification substrate assembly is detached from a solidified section of solidifiable material.

55. The apparatus of embodiment 54, wherein the solidified section of solidifiable material includes the substantially linear section of the solidifiable material.

56. The apparatus of embodiment 54, wherein when the solidification energy source moves in the first direction, the solidification substrate oscillates to detach the solidification substrate from the substantially linear section of the solidifiable material.

57. The apparatus of embodiment 54, wherein when the solidification energy source moves in the first direction, the solidification substrate moves in the first direction.

58. The apparatus of embodiment 57, wherein the solidification substrate includes a film assembly comprising a film, and when the solidification substrate moves in the first direction, the film is released from the solidified solidifiable material.

59. The apparatus of embodiment 57, in which the film is arranged in a frame, the frame is stationary, and when the solidification substrate moves in the first direction, the solidification substrate moves relative to the film in the first direction.

60. The apparatus of embodiment 57, in which the film is arranged in a frame, the frame is stationary with respect to the apparatus, and when the solidification substrate moves in the first direction, the solidification substrate moves with Relation to the movie in the first direction.

61. The apparatus of embodiment 54, wherein the solidification energy source comprises a matrix of light emitting diodes comprising a plurality of light emitting diodes extending along the second direction.

62. The apparatus of embodiment 54, comprising a linear solidification device, in which the linear solidification device comprises the solidification energy source and a rotating energy deflector, the linear solidification device is mobile in the first direction, the rotating energy deflector rotates in a plane that is substantially perpendicular

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in the first direction, and when the solidification energy source projects solidification energy to the rotating energy deflector, the rotating energy deflector deflects the solidification energy towards the solidifiable material to solidify the substantially linear section of the solidifiable material that extends to along a second direction.

63. The apparatus of embodiment 54, comprising a linear solidification device, in which the linear solidification device comprises the solidification energy source and a laser scanning micro mirror, the linear solidification device is mobile in the first direction and when the solidification energy source projects solidification energy on the laser scanning micro mirror, the laser scanning micro mirror scans the solidification energy along the solidifiable material to solidify the substantially linear section of the solidifiable material extending thereto along the second direction.

64. The apparatus of embodiment 54, in which the solidification substrate is partially cylindrical and has a longitudinal axis that extends along the second direction.

65. The apparatus of embodiment 64, wherein the solidification substrate assembly further comprises a stationary film, and the solidification substrate is disposed on the stationary film and the solidification energy source.

66. The apparatus of embodiment 65, further comprising a film set that includes the stationary film and at least one frame, in which the film set defines a reservoir for containing solidifiable material.

67. The apparatus of embodiment 66, further comprising at least one film stripping element, where when the solidification energy source moves in the first direction, the film stripping element moves in the first direction , and a part of the stationary film is disposed below the at least one film stripping member.

68. The apparatus of embodiment 66, further comprising a construction platform, in which the construction platform can move vertically upward from a position close to the stationary film to a vertically higher position separated from the stationary film, and the stationary film is located between the construction platform and the solidification energy source.

69. An apparatus for forming a three-dimensional object from a solidifiable material, comprising: a linear solidification device that can be moved in a first direction and comprising a solidification energy source in optical communication with a scanning device; in which the solidification energy source projects solidification energy in a second direction while moving in the first direction, when the linear solidification device projects solidification energy to the scanning device, the scanning device scans the solidification energy in a scanning address

70. The apparatus of embodiment 69, wherein the scanning device is a laser scanning micro mirror.

71. The apparatus of embodiment 69, wherein the scanning device is a rotating energy deflector.

72. The apparatus of embodiment 71, wherein the rotating energy deflector is a polygonal mirror.

73. The apparatus of embodiment 69, in which the first direction is substantially perpendicular to the scanning direction.

74. The apparatus of embodiment 69, in which the solidification energy source moves in the first direction at a first speed, the solidification energy scans the solidifiable material in the scanning direction at a scanning speed, and The scanning speed is at least 1000 times the first speed.

75. The apparatus of embodiment 69, further comprising at least one lens between the scanning device and a source of the solidifiable material, in which the lens is coated with an anti-reflective coating such that the lens transmits at least 95% of incident light having a wavelength ranging from about 380 nm to about 420 nm.

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76. The apparatus of embodiment 75, wherein the anti-reflective coating is a MgF2 coating.

77. The apparatus of embodiment 75, wherein the at least one lens is a first and a second F-Theta lens, the first F-Theta lens is between the laser scanning micro mirror and the second F-Theta lens, the first F-Theta lens has a face incident and a transmitting face, the second F-Theta lens has an incident face and a transmitting face, and the radius of curvature of the transmitting face of the first F-Theta lens is greater than the radius of curvature of the transmitting face of the second F-Theta lens.

78. The apparatus of embodiment 69, further comprising a collimation lens between the solidification energy source and the scanning device.

79. The apparatus of embodiment 78, in which the collimation lens is formed of BK-7 optical glass.

80. The apparatus of embodiment 78, wherein the collimation lens has an effective focal length of about 4.0 mm to about 4.1 mm.

81. The apparatus of embodiment 69, further comprising a solidification energy sensor in optical communication with the laser scanning micro mirror.

82. The apparatus of embodiment 81, further comprising a mirror in optical communication with the scanning device and the solidification energy sensor, in which when the solidification energy source projects solidification energy in the second direction during A synchronization operation, the solidification energy is diverted from the scanning device to the mirror, and the deviated solidification energy is reflected outside the mirror and transmitted from the mirror to the sensor.

83. The apparatus of embodiment 81, further comprising a neutral density filter that is positioned to receive and filter the light transmitted to the solidification energy sensor.

84. The apparatus of embodiment 70, wherein the apparatus includes a construction envelope, the construction envelope is a part of the solidifiable material in which the projected solidification energy can deviate from the scanning device, the angle of inclination of the Laser scanning micro mirror defines a deviated solidification energy position within the construction envelope along the scanning direction axis, and when the solidification energy sensor receives deviated solidification energy, the inclination angle of the linear scanning device corresponds to a limit of the building envelope.

85. The apparatus of embodiment 71, in which the apparatus includes a construction envelope, the construction envelope is a part of the solidifiable material in which the projected solidification energy can deviate from the scanning device, the rotational position of the Rotating energy deflector in the rotation plane defines a position of deviated solidification energy within the construction envelope along the scanning direction axis, and when the solidification energy sensor receives deviated solidification energy, the position of Rotation of the rotational energy deflector corresponds to a construction envelope limit.

86. The apparatus of embodiment 69, further comprising a solidification energy source controller that selectively activates the solidification energy source based on the shape information on the three-dimensional object.

87. The apparatus of embodiment 86, wherein the shape information comprises object data corresponding to a plurality of object cross-section strips, each object cross-section chain has a length defining a direction of length and a width that defines a width direction, and the plurality of strips are arranged in width along the width direction.

88. The apparatus of embodiment 87, in which the solidification energy source has an activation state, the solidification energy source controller selectively changes the activation state of the solidification energy source according to a plurality of sets of data strings, each plurality of sets of data strings corresponds to a layer of the three-dimensional object, and each set of data strings within each set of data strings corresponds to a cross-sectional string

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of the object and includes a plurality of numbers that define a time when the activation state of the solidification energy source changes.

89. The apparatus of embodiment 69, wherein the solidification energy source is a laser diode that projects light having a wavelength of approximately 380 nm to 420 nm.

90. The apparatus of embodiment 89, wherein the laser diode has an output power of at least about 300 mW.

91. The apparatus of claim 89, wherein the laser diode has a beam divergence of at least about 5 milliadianes.

92. The apparatus of embodiment 69, further comprising: a source of the solidifiable material defining a construction envelope, a first displacement region and a second displacement region, in which during a three-dimensional object construction operation , the three-dimensional object is constructed in the construction envelope but not in the first displacement region or the second displacement region; an end-of-path sensor in the first displacement region to detect an end-of-travel position of the solidification energy source in a direction away from the building envelope.

93. A method for synchronizing a timer with a solidification energy scan line position along a solidifiable material, comprising: activating a solidification energy source, in which the solidification energy source is in optical communication with a scanning device and the scanning device deflects the solidification energy received from the solidification energy source, and the diverted solidification energy is received by a solidification energy sensor; detecting the reception of solidification energy by the solidification energy sensor, in which the reception of solidification energy by the solidification energy sensor corresponds to the beginning of a line scan operation; initializing the timer to a specified value based on the detection of solidification energy reception by the solidification energy sensor.

94. The method of embodiment 93, wherein the solidification energy diverted from the solidification energy device is filtered by a neutral density filter before being received by the solidification energy sensor.

95. The method of embodiment 93, further comprising deactivating the solidification energy source within a deactivation time after receipt of a solidification energy sensor detection signal.

96. The method of embodiment 95, wherein the deactivation time is less than about 400 nanoseconds.

97. The method of embodiment 95, wherein the solidification energy sensor has a detection pulse corresponding to the time required for the deviated solidification energy to pass through a solidification energy sensor detection length, and the time Deactivation is less than the detection pulse.

98. The method of embodiment 97, wherein the detection length ranges from about 1.0 mm to about 4 mm.

99. The method of embodiment 93, wherein the scanning device is a rotating energy deflector.

100. The method of embodiment 93, wherein the scanning device is a laser scanning micro mirror.

101. The method of embodiment 93, wherein the step of activating a solidification energy source comprises activating a solidification energy source at a specific time with respect to the actuation signal of the scanning device.

102. The method of embodiment 101, wherein the activation signal of the scanning device is an activation signal supplied to a laser scanning micro mirror.

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103. The method of embodiment 101, wherein the activation signal of the scanning device is an activation signal supplied to a rotating motor operatively connected to a rotating energy deflector.

104. A method for reducing the storage capacity of a computer-readable medium required to store data of three-dimensional objects corresponding to a plurality of identical object layers, the method comprising: storing a first set of object layer data in a medium readable by computer, in which the object layer data comprises a first set of data strings, each data string is represented as d (0, m), m is a computer memory index value ranging from 0 to one less than the total number of Mmax data strings in the first set of data strings; executing in a processor instructions stored in a computer-readable medium to calculate a second set of object layer data of the first set of object layer data, in which the second set of object layer data comprises a second set of strings of data, each data string of which its represented as d (1, m), m is the computer memory index value that ranges from 0 to one less than the total number of Mmax data strings in the first set of data strings, where each value of d (1, m) is represented by the following equation: d (1, m) = d (0, Mmax-1 m).

105. The method of embodiment 104, wherein each data chain d (0, m) and d (1, m) comprises a plurality of time values, and each time value corresponds to an activation event of the solidification energy source.

106. The method of embodiment 104, wherein each data chain d (0, m) and d (1, m) further includes a chain index value, and each index chain value corresponds to a location at along an address in an object construction envelope.

107. The method of embodiment 104, wherein the first object layer data set and the second object data layer set correspond to adjacent layers of the three-dimensional object.

108. The method of embodiment 104, wherein the first set of object layer data corresponds to a first set of object layers formed by solidifying a solidifiable material in a first direction, and the second set of layer data. object corresponds to a second set of object layers formed by solidifying a solidifiable material in a second direction opposite the first direction.

109. A method of making a three-dimensional object, comprising: providing a set of string data, in which each string defines a region of an object layer along a scan axis direction; providing a linear solidification device, in which the linear solidification device supplies solidification energy along the direction of the scan axis at a scan speed that varies with the position along the scan axis; correcting the string data based on the variation of the scan speed with the position along the scan axis.

110. The method of embodiment 109, wherein the string data comprises a plurality of original string data values corresponding to solidification power source enhancement states, and the step of correcting the string data based on the variation of the scan speed with the position along the scan axis data string values for each corresponding original string data value in the plurality of original string data values, wherein each new string value of data is calculated based on a distance between the corresponding original string data value and a central point along the scan axis.

111. The method of embodiment 110, wherein the plurality of original string data values comprises a plurality of CPU marks.

112. The method of embodiment 110, wherein the plurality of original string data values comprises a plurality of scan axis distances with respect to a scan axis reference location.

113. The method of embodiment 110, in which each new string data value is related to the corresponding original data value as follows: New CPU marks = original CPU marks + ACPU marks * C where, New CPU marks is the new CPU mark value corresponding to the original CPU mark value for a given data chain; and ACPU marks are determined by subtracting the value of brands

of the CPU corresponding to a central point of the mark value of the original CPU; and C is a constant without dimensions.

114. The method of embodiment 110, further comprising constructing a test piece comprising a plurality of linear sections, each with a length along an axis perpendicular to the scan axis, and each new chain value of data is calculated at least one distance between adjacent linear sections in the test piece.

115. The method of embodiment 114, wherein the step of constructing a test piece comprises providing chain data corresponding to a plurality of equally separate linear sections, and solidifying a solidifiable material according to the chain data.

Claims (14)

5 10 fifteen twenty 25 30 35 40 Four. Five fifty 55 60 65 Claims 1. An apparatus for forming a three-dimensional object from a solidifiable material, comprising: a solidification energy source (90; 90a; 90b); Y a linear scanning device (92) in optical communication with the solidification energy source (90; 90a; 90b); characterized because the solidification energy source (90; 90a; 90b) is mobile in a first direction and operable to project solidifiable energy selectively in a second direction on the linear scanning device (92) while moving in the first direction; a solidification energy sensor (324) in optical communication with the linear scanning device (92); which is positioned such that the solidification energy sensor (324) can receive energy diverted from the linear scanning device (92); Y a linear solidification microcontroller connected to the solidification energy sensor (90; 90a; 90b) and programmed to initialize a timer upon receiving a signal from the solidification energy sensor (324); in which the linear scanning device (92) is separated from the solidification energy source (90; 90a; 90b) and the solidification energy device (92) is separated from the solidification energy sensor (324), in which the device Linear scanning (92) is operable to scan solidification energy received from the solidification energy source (90; 90a; 90b) in a plurality of linear patterns along a solidifiable material source, while the linear scanning device (92) moves in a first direction, each linear pattern has a length along the second direction and The solidification energy sensor (324) is operable to receive solidification energy from the solidification energy source (90; 90a; 90b) each time the linear scanning device (92) scans a linear solidification energy pattern at along the source of the solidifiable material. 2. The apparatus of claim 1, further comprising a linear solidification controller, wherein the linear solidification controller is programmed to activate the solidification energy source (90; 90a; 90b) to transmit solidification energy to the sensor solidification energy (324) each time the linear scanning device (92) scans a linear pattern of solidification energy along the source of the solidifiable material. 3. The apparatus of claim 1, wherein during a solidification operation, the linear solidification controller selectively activates and deactivates the solidification energy source (90; 90a; 90b) in correspondence with the plurality of linear patterns. 4. The apparatus of claim 1, wherein the solidification energy source is a laser diode (90; 90a; 90b). 5. The apparatus of claim 1, wherein the solidification energy sensor (324) is a photodiode. 6. The apparatus of claim 1, wherein the linear scanning device comprises a rotating polygonal mirror (92) having a plurality of facets (94a-94f), and each facet (94a-94f) has a rotating position in which facet (94a-94f) is in optical communication with the solidification energy source (90; 90a; 90b) and the solidification energy sensor (324). 7. The apparatus of claim 6, wherein the solidification energy source (90; 90a; 90b) includes a construction envelope limit (344), the apparatus further comprises a mirror (332) immediately close to the envelope limit construction (344), the mirror (332) is in optical communication with the solidification energy sensor (324) and each facet (94a - 94f) has a rotational position in which the facet (94a-94f) is in communication optics with the mirror (332). The apparatus of claim 1, further comprising a neutral density filter (326) positioned to filter the light received by the solidification energy sensor (324). 9. The apparatus of claim 1, further comprising a mirror (332) in optical communication with the linear scanning device (92) and the solidification energy sensor (324). 5 10 fifteen twenty 10. The apparatus of claim 9, wherein the solidification energy sensor (324) and the mirror (332) are separated from the linear scanning device (92). 11. The apparatus of claim 1, wherein the solidification energy source (90; 90a; 90b) is separated from the linear scanning device (92) along the second direction. 12. The apparatus of claim 1, wherein the linear scanning device (92) has a maximum solidification energy position along the second direction, and the solidification energy sensor (324) is located in a position which corresponds to the maximum solidification energy position along the second direction. 13. The apparatus of claim 1, wherein the solidification energy sensor (324) is positioned to indicate when the projected solidification energy along the second direction has reached one selected between the beginning of the path and the end of the trajectory. 14. The apparatus of claim 1, further comprising a housing (96) with a linear opening (100), wherein the solidification energy source (90; 90a; 90b), the solidification energy sensor (324) and the linear scanning device (92) are arranged in the housing (96) so that when the housing (96) moves in the first direction, the linear scanning device (92), the solidification energy source (90 ; 90a; 90b) and the solidification energy sensor (324) move in the first direction, and the solidification energy sensor (324) is located between the linear opening (100) and the linear scanning device (92) .